Bagging machine with filling expansion

Abstract

Bagging apparatus is provided. The bagging apparatus can include a bag mover configured to move a packaging material configured to define a bag having a first wall and a second wall surrounding an interior cavity configured to contain an object for shipping within the interior cavity, the first wall including an expandable material having an expandable configuration and expandable to the expanded configuration to provide a cushion to the first wall to protect the object contained within the interior cavity. The bagging apparatus can also include an expanding apparatus configured to apply an expanding condition to the packaging material, the expanding condition configured to cause the expandable material to expand from the expandable configuration to the expanded configuration.

Description

Technical Field

[0001] This disclosure generally relates to packaging for transporting articles. More specifically, this disclosure relates to systems and methods for expanding expandable packaging containers to provide cushioning for objects contained within the expandable packaging containers.

[0002] Cross-references to related applications

[0003] This application claims U.S. Provisional Patent Application No. 63 / 046,828, entitled "Expandable Wall Bass in Series," filed July 1, 2020; U.S. Provisional Patent Application No. 62 / 706,110, entitled "Expandable Wall Bass in Series," filed July 31, 2020; U.S. Provisional Patent Application No. 63 / 069,571, entitled "Expandable Wall Bass in Series," filed August 24, 2020; U.S. Provisional Patent Application No. 63 / 105,420, entitled "Post-Expansion Packaging," filed October 26, 2020; and U.S. Provisional Patent Application No. 63 / 105,420, entitled "Post-Expansion Packaging," filed October 29, 2020. Priority is claimed in U.S. Provisional Patent Application No. 63 / 107,333 entitled “PACKAGING” and U.S. Provisional Patent Application No. 63 / 107,312 entitled “PACKAGING MATERIAL WEB WITH STRIP SEALS”, filed on October 29, 2020, each of which is incorporated herein by reference in its entirety. Background Technology

[0004] Traditional low-density protective packaging is manufactured in standard bulk, low-density configurations. These configurations may include pre-formed and filled fluid chambers (e.g., bubble wrap materials), pre-expanded foam, filler inserts, etc. These bulk, low-density configurations provide packaging support during transport. However, they must be transported to the packaging and shipping location before they can be used for packaging.

[0005] Because traditional protective packaging is already produced in a large-volume, low-density configuration, it must be transported in this way. This increases the total volume of packaging material even before it is used for packaging, thereby increasing the transportation costs of transporting the packaging material to the packaging and shipping locations, and reducing the amount of product that can be stored at these locations before it is needed.

[0006] For at least these reasons, there is a need for systems and methods for producing packaging materials with small volume and high density configurations that can be subsequently scaled up. Summary of the Invention

[0007] According to various embodiments of the present disclosure, a bagging apparatus is provided. The bagging apparatus may include a bag transferor configured to transfer packaging material configured to define a bag having a first wall and a second wall surrounding an inner cavity configured to contain an object for transport. The first wall includes an extension material having an extendable configuration and extendable to the extendable configuration to provide padding to the first wall to protect the object contained within the inner cavity. The bagging apparatus may also include an extension means configured to apply an extension condition to the packaging material, the extension condition being configured to extend the extendable material from the extendable configuration to the extendable configuration.

[0008] According to various embodiments, the bag transferor includes a sealer configured to seal an opening between a first wall and a second wall leading to an inner cavity to retain an object therein. According to various embodiments, the sealer is a heat sealer configured to form a heat-sealed portion between the first wall and the second wall.

[0009] According to various embodiments, the bagging device further includes a bag opener configured to engage an opening and open the opening so that an object can be received into the cavity through the opening. According to various embodiments, the bag opener includes a fan configured to apply air pressure directed toward the opening. According to various embodiments, the bag opener includes a plurality of fingers for extending into the opening and maintaining the opening in an open configuration. According to various embodiments, the bag opener includes one or more suction devices configured to apply a suction force to at least one wall, which is configured to pull open the opening.

[0010] According to various embodiments, the bagging device further includes a bag mover configured to move the bag to the expansion device and the bag transferor. According to some embodiments, the expansion device is positioned along the bagging device such that it is configured to expand the expansion material before the sealer seals the opening. According to some embodiments, the expansion device is positioned along the bagging device such that it is configured to expand the expansion material while the sealer seals the opening. According to some embodiments, the expansion device is positioned along the bagging device such that it is configured to expand the expansion material after the sealer seals the opening.

[0011] According to various embodiments, the packaging material is configured to define a series of bags, these bags being separable from other bags, and includes a separator configured to separate adjacent bags within the series. According to various embodiments, the separator includes a cutter configured to cut the packaging material. According to various embodiments, the expansion device is configured to raise the temperature of the expansion material to an expansion temperature sufficient to reduce the density of the expansion material and cause the expansion material to expand into an expansion configuration. According to various embodiments, the expansion device is configured to heat air and direct the heated air to the packaging material, thereby raising the temperature of the expansion material to the expansion temperature.

[0012] According to various embodiments, the bagging device may include a bag folder configured to fold packaging material over itself to provide a first wall and a second wall.

[0013] According to various embodiments, a packaging material web material is provided. The packaging material web material may include a web comprising a plurality of packaging containers arranged in series along the longitudinal direction of the web, each packaging container including overlapping first and second walls that are sealed to each other at a plurality of inter-wall seals, the inter-wall seals including a plurality of transverse seals extending laterally across the web, defining an inner cavity between the walls of each packaging unit, the inner cavity being configured to receive an object therein, wherein the walls are not sealed on the longitudinal side of the inner cavity, each inner cavity facing an adjacent packaging container to provide an opening to the inner cavity configured to receive an object into the inner cavity. The packaging material web material may further include an extension member disposed in at least one wall in an unextended configuration, the extension member being extensible to an extended configuration, wherein the extension material is configured to provide cushioning within the wall for an object contained in the inner cavity. Attached Figure Description

[0014] The foregoing and other features of this disclosure will become clearer from the following description taken in conjunction with the accompanying drawings and the appended claims. It should be understood that these drawings depict only a few examples according to this disclosure and should therefore not be considered as limiting the scope of this disclosure, which will be described below with additional specificity and detail using the drawings, in which:

[0015] Figure 1 This is a top perspective view of an embodiment of a layer used to form a wall;

[0016] Figure 2 For example, using Figure 1 A top view of the wall panel formed by the layers;

[0017] Figure 3 For example Figure 2 A longitudinal cross-sectional view of a web, which is folded and glued to form a web of a connected packaging container according to one embodiment;

[0018] Figure 4A This is a top cross-sectional view of another embodiment of the web;

[0019] Figure 4B yes Figure 4A Bottom perspective view of the web, which is folded and glued to form a continuous packaging container;

[0020] Figure 4C yes Figure 4B A longitudinal cross-sectional view of the web;

[0021] Figure 5 It is used to form a packaging container according to one embodiment, for example Figure 1 A top view of the packaging wall, like the wall itself;

[0022] Figure 6 It is by Figure 5 A longitudinal cross-sectional view of the packaging container formed by the walls;

[0023] Figure 7 For example, Figure 6 A perspective view of a complete roll-up supply web of a separable packaging container constructed as shown.

[0024] Figure 8 For example, Figure 6 A perspective view of the complete supply web of a detachable packaging container in a fan-shaped configuration, as shown.

[0025] Figure 9A and 9B These are used to convert inventory materials into, for example, Figure 3 Side and top views of a supply chain system for detachable packaging containers constructed as shown.

[0026] Figure 10 This is a cross-sectional side view showing a weakened region in the web of a separable packaging container constructed, for example, as shown in the figure above.

[0027] Figure 11 It is along Figure 9A A longitudinal cross-sectional view of section AA;

[0028] Figure 12A This is a schematic top view of an inflatable web having an inflatable sub-chamber according to one embodiment;

[0029] Figure 12B and 12C It has Figure 12A Cross-sectional views of various embodiments of the arrangement of inflatable expansion material;

[0030] Figure 12D yes Figure 12C A cross-sectional view of one embodiment of an inflatable expansion material;

[0031] Figure 13A and 13B These are perspective and cross-sectional side views of an extension and bagging device according to one embodiment;

[0032] Figure 14A This is a cross-sectional side view of an expansion and bagging device according to one embodiment;

[0033] Figure 14B This is a cross-sectional side view of an expansion and bagging device according to one embodiment;

[0034] Figure 14C This is a cross-sectional side view of an expansion and bagging device according to one embodiment;

[0035] Figure 15 This is a perspective view of an extended and bagging device according to one embodiment;

[0036] Figure 16A , 16B 16C, 16D, 16E, 16F, 16G, 16H and 16I are perspective views of bag opening and sealing assemblies of extended and bagging devices according to various examples of the present disclosure;

[0037] Figure 17A and 17B These are rear and front perspective views of an extension and bagging device according to one embodiment;

[0038] Figure 18 This is a perspective cross-sectional view of an expansion device for use with an inflatable web of packaging material, according to one embodiment; and

[0039] Figure 19 This is a flowchart of a method for generating one or more packaging elements according to various embodiments. Detailed Implementation

[0040] In the following detailed description, reference is made to the accompanying drawings, which form part of this detailed description. In the drawings, similar symbols generally identify similar components unless the context otherwise requires. The illustrative examples described in the detailed description, drawings, and claims are not intended to be limiting. Other examples may be utilized and other changes may be made without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that, as shown in the general description and drawings herein, various aspects of this disclosure can be arranged, substituted, combined, separated, and designed in a variety of different configurations, all of which are implicitly contemplated herein.

[0041] Some aspects of this disclosure relate to packaging elements formed from packaging materials. Some packaging elements formed from packaging materials include liners and sheets that include a single wall. Some packaging elements formed from packaging materials include packaging units configured to cushion one or more objects during transport. Packaging units may include, for example, liners and packaging containers. Packaging containers include multiple walls that surround an inner cavity for storing one or more products. Some packaging containers include bags and envelopes such as mailbags, which can be manufactured and then filled with items to be transported at a later time.

[0042] Some embodiments of this disclosure include extended walls. Some extended walls include expandable walls that are in an unextended configuration and can be extended later. Some extended walls include extended walls that are already in an extended configuration. An extended wall may include one or more extension members configured to extend the extended wall. An extension member may include one or more inflatable chambers. Some inflatable chambers include inflatable chambers configured to receive fluid (e.g., air or other suitable gaseous or non-gaseous fluids). Some inflatable chambers include inflated fluid chambers. Inflated fluid chambers may include, for example, preformed chambers (e.g., vacuum-formed bubbles). An extension member may include one or more extension materials. Some extension materials include expandable materials configured to extend by applying one or more extension conditions (e.g., thermal or chemical reactions or other suitable methods). Some extension materials include extension materials that extend from the applied dimension.

[0043] The various seals described herein include at least one sealing material. In a preferred embodiment, the packaging material web includes multiple sealing materials. The sealing material includes an adhesive element. The adhesive element includes an adhesive or cohesive material to provide an adhesive or cohesive surface, respectively. A combination of adhesive and cohesive surfaces can be used. The adhesive element can be applied directly to the exposed surface of the material by suitable known methods, or it can be applied to an adhesive tape (e.g., double-sided tape), or other suitable methods. In some embodiments, the sealing material includes polyethylene. In some embodiments, the sealing material includes a heat-sealable material. In some embodiments, the sealing material includes a material used as a cold adhesive. It should be noted that other suitable sealing materials may be used in combination with or in lieu of the exemplary sealing materials described herein.

[0044] As used herein, adhesive elements are made of materials that bond to other types of surfaces, preferably, for example, those commonly found near protective packaging (e.g., plastic, paper, or metal). Adhesives can adhere to opposing surfaces without relying on opposing surfaces having the same or complementary materials for adhesion to form a bond between two surfaces. Examples of suitable adhesives include liquid adhesives and pressure-sensitive adhesives. Pressure-sensitive adhesives can be selected that adhere after a slight initial external pressure is applied to form a bond. These examples include water-based acrylic pressure-sensitive adhesives, similar to adhesives applied to packaging tapes, which typically hold two surfaces together simply through surface contact under slight initial external pressure. Examples may include dry adhesives, which generally do not require activation with water, solvents, or heat and bond firmly to many different surfaces. Pressure-sensitive adhesives with corrosive and / or permanent tack at room temperature can be selected. The application and use of pressure-sensitive adhesives can be automated. When used for assembly, pressure-sensitive adhesives, which do not require setup or have longer curing times, can save time compared to using typical liquid adhesives. It is preferable to use pressure-sensitive adhesives for immediate bonding, allowing the manufacturing process to continue uninterrupted, which can significantly save time and labor. Examples of water-based acrylic pressure-sensitive adhesives include those called RHOPLEX N-1031 emulsion, RHOPLEX N-580 emulsion, and RHOPLEX N-619 emulsion. Other emulsion polymer or acrylic polymer blend adhesives are also known, and other suitable types of adhesives and / or contact adhesives can be used.

[0045] The cohesive material of an adhesive element causes one surface to adhere to the opposite surface by contacting with the same or complementary cohesive material to form a bond between two surfaces. The polymers (where opposite polymers adhere to each other) do not adhere sufficiently to other substances to bond to those other substances (e.g., other surfaces of protective packaging material without cohesive elements, the surface of a container, the surface of the product to be transported), or in some cases, their adhesion is very weak compared to the bond formed by their adhesion to each other. The polymers can be pressure-sensitive polymers, where pressure is required to activate the bond. Examples of suitable cohesive materials that can be made into cohesive adhesive elements include natural and synthetic latex-based polymers. In some embodiments, the cohesive material is applied as a liquid to appropriate portions of the protective packaging material, and in other embodiments, it is applied in other known forms. Certain types of polymers (e.g., polymers made from latex) are mixed with water without additional adhesive to bond to corresponding non-adhesive portions of the protective packaging material and remain adhered to the exposed surfaces of the protective packaging material to which the polymer has been applied after drying. In some embodiments, the cohesive material may be mixed with an adhesive that is typically applied as a liquid to the protective packaging material. The adhesive may be selected such that after the polymer and adhesive mixture is applied to the protective packaging material (e.g., to a film layer), the adhesive evaporates, leaving the polymer bonded to the non-cohesive protective packaging material (e.g., applied to a film or sheet of paper). One method of liquid application is spraying, but brushing or other suitable methods may also be used. Furthermore, other suitable methods of applying the polymer to the surface of the non-cohesive material may be used alternatively.

[0046] refer to Figure 1 This illustrates a supply web 10 of packaging material with a low-volume, high-density configuration. Web 10 comprises one or more layers of polymer, cellulose-based material (e.g., paper), or other suitable material. Figure 1 In this embodiment, the web 10 forms an extended wall and includes multiple layers 12, 14. The wall is provided as a multi-layered structure. In an alternative embodiment, one or more walls are multi-layered and / or single-layered structures.

[0047] The web 10 includes a first layer 12 and a second layer 14. The first layer 12 includes one or more seals 16, 18 formed thereon or applied thereon, which may include a sealing material. The one or more seals 16, 18 include one or more longitudinal seals 16 bonded along one or more longitudinal edges 26 of the first layer 12. The one or more seals 16, 18 may additionally or alternatively include one or more transverse seals 18. The one or more transverse seals 18 extend to one or more longitudinal edges 26 of the first layer 12. In other embodiments, the transverse seals 18 extend across a portion of the first layer 12.

[0048] Layers 12 and 14 may include paper (e.g., cardboard, kraft paper, fiberboard, pulp paper, recycled paper, newsprint, and coated paper (e.g., paper coated with wax, plastic, waterproof, and / or antifouling materials)), plastic, cellulose, foil, polyethylene, or synthetic materials, biodegradable materials, and / or other suitable materials having appropriate thickness, weight, and dimensions. Layers 12 and 14 may include recyclable materials (e.g., recyclable paper). Layers 12 and 14 may include one or more substrates. In some embodiments, the one or more substrates include a paper substrate. The paper substrate may include layers of material applied thereon. The material layers may include one or more layers of waterproof, airtight, adhesive, cohesive, heat-sealing, other suitable material layers, and / or combinations thereof.

[0049] The web 10 includes an expandable element. The expandable element includes an expanding material 20. The expanding material 20 may be located between a first layer 12 and a second layer 14. The expanding material 20 is applied to one of layers 12 and 14. The expanding material 20 is applied to the first layer 12. In other embodiments, the expanding material 20 is applied to the second layer 14 and / or both the first layer 12 and the second layer 14. The expanding material 20 is applied in a regular shape (e.g., circular, elliptical, square, rectangular, triangular, etc.) or an irregular shape. The expanding material may be applied to the web as a continuous layer or in a pattern. The pattern may be configured such that when the layers are pressed together, the expanding material spreads out, thereby forming a continuous layer. In some embodiments, the web 10 includes one or more vents or vent openings configured to generate gas (e.g., water vapor) by applying or expanding the expanding material 20.

[0050] An expansion device is provided to expand an expanded material. The expansion device is activated by an expansion initiator. In some embodiments, the expanded material comprises multiple materials separated by a barrier, which expand into an expanded configuration when mixed or in contact with each other. In some embodiments, the expanded material comprises a matrix that can be expanded by the expansion device. Before the expanded material expands, while the expanded material is still in a scalable state (i.e., when the expanded material is scalable), the matrix may be a fluid, such as a gel or liquid. This allows it to be ready for application onto a layer. In other embodiments, the scalable material is provided as a solid and / or may pass through a gel or fluid phase. The expansion initiator may be thermal and / or mechanical and / or chemical and / or may include other suitable initiation properties for activating the expansion device. For example, the expansion initiator may be one or more of thermal, pressure, chemical reaction, and / or other suitable expansion initiators. The expansion device may include a reactive component, a chemical catalyst, a foaming agent, a heating agent (which can apply heat to the expanded material and / or raise the temperature of the expanded material), and / or other suitable expansion devices. In some embodiments, the expansion device is kept separate from the matrix by means of a barrier and may be held within another structure (e.g., a microsphere shell) for this purpose. Once expanded, the extension material 20 provides a cushioning pad that is configured to protect one or more items / products / etc. positioned against the first layer 12 or the second layer 14.

[0051] In some embodiments, the matrix may include one or more polymers, including emulsion-based polymers. The one or more polymers may include vinyl acetate, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetate copolymers, polyvinyl alcohol copolymers, dextrin-stabilized polyvinyl acetate, vinyl acetate copolymers, ethylene copolymers, vinyl acrylic acid, styrene acrylic acid, acrylic acid, styrene-butyl rubber, polyurethane, polyolefins, biodegradable materials (e.g., cellulose and starch), and / or other suitable extended materials.

[0052] In some embodiments, the matrix may include a polyolefin-based adhesive or a polyolefin dispersion. The polyolefin dispersion may include polyethylene and / or polypropylene, thermoplastic polymers, polymer stabilizers including at least one polar polymer, water, and / or other suitable polyolefin dispersions. Suitable polyolefin dispersions may include, for example, HYPOD manufactured by Dow Chemical. TM Or other suitable polyolefin dispersions.

[0053] In some embodiments, the matrix is ​​a water-based adhesive. Water-based adhesives may include water-based polymers.

[0054] In some embodiments, the matrix is ​​based on starch in natural or synthetic forms. In some embodiments, the starch is in the form of milled micronized starch. The diameter of the milled starch particles is between about 12 micrometers and about 20 micrometers. In some embodiments, the starch-based matrix comprises one or more of water or other solvents, surfactants, polar binders, or other fillers. In some embodiments, for example, the matrix comprises up to 50% water. In some embodiments, the matrix comprises, for example, 30-40% starch.

[0055] Some embodiments include a barrier separating the extension device from the matrix. A suitable barrier is a microsphere shell containing a foaming agent, chemical catalyst, or chemically reactive component as the extension device. Other types of barriers may be used alternatively.

[0056] In some embodiments, the expansion device includes a plurality of microspheres that, for example, expand and / or rupture upon the application of sufficient heat. The microspheres may include a shell and a core. Suitable shells may include, for example, one or more thermoplastic polymers, such as polyacrylonitrile or PVC, as well as glass, rubber, starch, cellulose, ceramics, or other suitable materials. In some embodiments, the plurality of thermally expandable microspheres include a solid, liquid, or gaseous core made of one or more of hydrocarbons, water, or other suitable chemicals that can be activated to expand or rupture the microsphere shell. In some embodiments, the microspheres may include a biodegradable material, such as cellulose.

[0057] Devices such as microspheres can be mixed with the matrix before being applied to the web, or provided on the matrix after it has been applied to the web by mixing or forcing the microspheres into the matrix.

[0058] In some embodiments, the microspheres have an expansion temperature (Texp) and a maximum temperature (Tmax) at which they begin to expand and rupture if heated above Tmax. The Texp of the microspheres is not particularly limited but is typically between about 60°C and a maximum of about 250°C. The Tmax of the microspheres is typically between about 80°C and a maximum of about 300°C. In some embodiments, Tmax is above 300°C. The microspheres are selected based on their maximum expansion temperature, depending on whether rupture is required. Tmax depends on a variety of properties, including the physical properties of the microspheres, the physical properties of the matrix, and the physical properties of the matrix and the layers on which the microspheres are deposited. Heat can be generated by a suitable method (e.g., radio frequency radiation or other suitable methods). In some embodiments, radio frequency radiation is applied to the expansion material 20 at a frequency of about 10-45 MHz or a frequency suitable for the microsphere composition and matrix material. In other embodiments, other frequencies may be used. The selected heating parameters depend on one or more expansion materials 20 used. Suitable microspheres are known in the art.

[0059] In some embodiments, the expanding device includes a foaming agent, such as a gas or gas mixture. Examples of suitable gases include air, carbon dioxide, nitrogen, argon, helium, methane, ethane, propane, isobutane, n-butane, neopentane, etc. In some embodiments, the gas or gas mixture is added to the expanding material mechanically. Examples of mechanical methods include stirring the expanding material or foaming the expanding material to inject air or other gases into the expanding material and increase its volume. In other embodiments, the gas or gas mixture may also be encapsulated in microspheres. When the microspheres are activated, they expand and may rupture. The expansion of the microspheres causes the expanding material to expand. The rupture of the microspheres releases their contents, resulting in foaming and expansion of the expanding material. In some embodiments, the web 10 includes one or more vents or vent openings configured to allow gases (e.g., water vapor) generated by the application or expansion of the expanding material 20.

[0060] In some embodiments, the expansion device includes one or more reactive components that induce a chemical reaction to expand the matrix. The chemical reaction may include a mixture of two reactive components that react to generate foam. In some embodiments, a catalyst is used to increase the rate of the chemical reaction. In some embodiments, the two reactive components are separated by a barrier before mixing and expansion. The barrier separating the reactive components may be the shell of a microsphere, wherein the core of the microsphere contains one or more reactive components, and the rupture of the microsphere releases its contents into one or more other reactive components, inducing a foam-forming reaction. Other barriers may also be used, such as walls, capsules, or other barrier-forming containers. Examples of reactive components that induce expansion include mixing a liquid isocyanate with a multi-component liquid mixture called a polyurethane resin. When combined, these components release carbon dioxide and water vapor to generate polyurethane foam. Other reactive components that form foam upon mixing may be used.

[0061] In some embodiments, the extended material 20 cures as it expands, but in other embodiments, the extended material 20 forms a gel or has another physical phase, depending on the article's construction. The expanded extended material 20 is configured to form protective filler regions and / or insulating regions. The curing method of the extended material is selected based on its physical properties and can be achieved by methods such as thermosetting, drying (e.g., air drying), curing, or by other suitable processes (e.g., known methods of transforming a material from a fluid to a solid). For example, thermosetting plastics can be cured irreversibly by curing, while the curing of thermoplastic plastics can be reversible.

[0062] In some embodiments, the extension material 20 is applied in a pattern. The pattern, distribution, and / or concentration of the extension material 20 are selected to obtain desired filling and / or insulating properties. In this embodiment, the extension material 20 is applied in a dotted pattern. The dots may be points, squares, circles, large and / or small shapes, or polygons. Alternatively, other suitable patterns may be used, such as lines, arcs, circles, ellipses, squares, rectangles, polygons, or combinations thereof. The extension material 20 is applied to a portion of the surface of one or more layers 12, 14 of the web 10. Alternatively, the extension material 20 may be applied to the entire surface of one or more layers 12, 14. In this embodiment, the extension material is applied with a relatively uniform thickness. Alternatively, other thicknesses, such as variable thicknesses, may be used. In some embodiments, the lines of the web 10 may be without the extension material 20 to form natural hinge lines or areas that are more flexible than other areas in which the extension material 20 extends. In some embodiments, pressure is applied to the extension material 20 during or after extension to form hinge lines or areas that are more flexible than other areas.

[0063] The second layer 14 includes one or more sealing portions 22, 24 containing sealing material. The one or more sealing portions 22, 24 may be configured to complement the sealing portions 16, 18 of the first layer 12 and include one or more longitudinal sealing portions 22 adhered along one or more longitudinal edges 28 of the second layer 14. The one or more sealing portions 22, 24 of the second layer 14 include one or more transverse sealing portions 24. The one or more transverse sealing portions 24 extend to one or more longitudinal edges 28 of the second layer 14. In other embodiments, the one or more transverse sealing portions 24 extend across a portion of the second layer 14.

[0064] According to some embodiments, in addition to or in lieu of the extension material 20, the web 10 includes one or more inflatable chambers, for example... Figure 12A-12D The inflatable chambers are described in the illustrative text.

[0065] The first layer 12 is bonded to the second layer 14. After bonding the first layer 12 and the second layer 14, one or more external sealing materials are applied to the outside of the web 10 to form one or more external sealing portions 30, 32, 36 (e.g., Figure 2 (As shown). One or more longitudinal seals 30 are applied to the outer longitudinal edge 34 of the web 10, and one or more transverse seals 32 are applied between the one or more longitudinal seals 30. Then along direction 42 (as shown). Figure 5 (As shown) The web 10 is fed through a folding device that folds the web 10. In this embodiment, the web 10 is folded along the folding edge 40. In other embodiments, the web may alternatively have multiple folding edges 40.

[0066] The web 10 may include one or more external longitudinal seals 30 and one or more transverse seals 32, 36. The transverse seals 32 form a bottom seal of one or more packaging containers 44. In this embodiment, the transverse seals 36 are configured to seal an opening in the packaging container 44 after the product is inserted into the cavity of the packaging container 44. According to this embodiment, the transverse seals 32, 36 have different seal types. In this embodiment, one or more transverse seals 32, 36 have a seal type different from that of one or more longitudinal seals 30. In other embodiments, one or more of the transverse seals 32, 36 may alternatively have a seal type similar to that of one or more longitudinal seals 30. According to some embodiments, in some embodiments, one or more longitudinal seals 30 may be formed at a temperature different from the temperature required to form a seal using one or more transverse seals 32, 36. This allows a seal activated at one temperature to be activated at a different time than the activation time of one or more seals activated at other temperatures. In some embodiments, each seal 30, 32, and 36 may be a heat-activated seal.

[0067] Web 10 may include one or more web layers having surfaces including a first region and a second region, wherein when the corresponding first region (corresponding to, for example) Figure 2 The areas where the middle sealing portions 30 and 32 are located overlap each other and the corresponding second areas (corresponding to, for example) Figure 2When the regions of the central sealing portion 36 located thereon overlap each other, the overlapping first and second regions together surround a cavity defined between at least one web layer. The web 10 may include a first sealing material disposed in the first region and configured to seal corresponding first regions of at least one web layer together when a first condition is applied to the first sealing material. The web 10 may include a second sealing material disposed in the second region and configured to seal corresponding second regions of at least one web layer together when a second condition is applied to the second sealing material. The second sealing material is configured such that the first condition applied to the second sealing material is insufficient to seal the second sealing material. In some embodiments, the first and second sealing materials are different materials. The corresponding first regions are sealed to each other by the first sealing material, while the second sealing material is unsealed, forming an opening to the inner cavity 46, which is configured to receive an object into the inner cavity. In some embodiments, the second sealing material is configured to seal the closed opening. In some embodiments, the corresponding first regions are sealed to each other and the corresponding second regions are adjacent to each other. In some embodiments, at least one web layer includes a longer web layer and a shorter web layer, a second region of the longer web layer being located on the longer web layer in a direction facing the inner cavity, and a second region of the shorter web layer being located on the shorter web layer in a direction outward from the inner cavity.

[0068] In some embodiments, one or more longitudinal seals 30 and one or more transverse seals 32, 36 include sealing materials configured to establish a seal without the application of heat. For example, one or more longitudinal seals 30 and one or more transverse seals 32, 36 include pressure-activated adhesives, cold adhesives (e.g., collagen-based adhesives, polyvinyl acetate-based adhesives, or other suitable adhesives), and / or other suitable sealing materials. This prevents the expansion material 20 from activating and expanding simultaneously with the activation of one or more longitudinal seals 30 and / or one or more transverse seals 32, 36.

[0069] In this embodiment, one or more transverse seals 32, 36 are disposed at longitudinally spaced locations on the web 10 and extend substantially entirely transversely across the web 10 between its longitudinal edges 34. In other embodiments, one or more of the transverse seals 32, 36 may alternatively extend over a portion of the transverse length of the web 10. The transverse seals 32, 36 are separated by a gap 38 at a distance 35. According to some embodiments, the gap 38 is configured to act as a vent to discharge one or more gases generated during the expansion process of the expandable element.

[0070] like Figure 3As shown, a cross-section of a folded web 10 is exemplaryly depicted according to various embodiments of the present disclosure. The web 10 is folded at a fold edge 40 to form a bag structure with an inner cavity 46. One side of the folded web 10 is folded, while the other side is sealed by a longitudinal seal 30, forming a seam. The longitudinal seal 30 includes a heat-activated seal (e.g., a heat-activated adhesive or other suitable heat-activated seal), one or more strip seals, one or more pressure-activated seals (e.g., a pressure-activated adhesive or other suitable type of pressure-activated seal), or other suitable type of seal. A sealing material may be applied to the perimeter. In some embodiments, the sealing material has a generally uniform width. In some embodiments, the sealing material is applied with varying widths. The web 10 may have one fold edge 40, or alternatively, multiple fold edges 40.

[0071] Once folded and flattened, the longitudinal seal 30 is aligned. In some embodiments, the seal 30 is aligned at the longitudinal edge 34 of the web 10, such as... Figure 3 As shown in FIG. 4. In other embodiments, the sealing portion 30 is aligned at a location between multiple folded edges 40 to form a seam 48 at the unfolded longitudinal edge 34 of the web. The web 10 includes one or more weakened regions 50 extending laterally (e.g., generally perpendicular to) the longitudinal edge 34. The seam 48 includes a longitudinal edge 34 overlapping another longitudinal edge 34, wherein sealing material is applied to an upper region of one longitudinal edge and / or a lower region of the other longitudinal edge to form the sealing portion 48. In some embodiments, the sealing portion 48 may be a finned seal or other suitable sealing configuration.

[0072] In this embodiment, one or more transverse seals 32 are disposed at longitudinally spaced locations on the web 10 and extend substantially entirely transversely across the web 10 between its longitudinal edges 34. In other embodiments, one or more transverse seals 32 extend over a portion of the transverse length of the web 10.

[0073] like Figures 4A-4CAs shown, the packaging material web includes a first overlapping layer 12 and a second overlapping layer 14, each including a hinge region 55. The hinge region 55 is arranged to fold the overlapping layers together at a hinge line 57 extending through the hinge region 55 to divide the overlapping layers into a first wall portion 61 and a second wall portion 63 on opposite sides of the hinge line, such that the wall portions fold around the hinge line 57 into a folded configuration defining a cavity 46 therebetween, the cavity 46 being configured to receive and accommodate an object. In some embodiments, the packaging material web includes an expandable material configured to cushion the object when in the expanded configuration. The expandable material is arranged between the first and second layers in a main fill region 67, wherein the hinge region between the layers has less expandable material than the main fill region 67, such that the hinge region is thinner than the main fill region in the folded configuration. The web also includes a sealing material arranged to secure the wall portions in the folded configuration, such that the first and second walls define a packaging unit. In some embodiments, the web also includes a longitudinal sealing material. In some embodiments, one or both longitudinal edges are sealed.

[0074] In some embodiments, the hinge region 55 is substantially free of expandable material, thereby providing a gap 59 between the portions of the main filler region 67 on the first wall portion 61 and the second wall portion 63. In some embodiments, the hinge region 55 comprises less than 30% of the expandable material that is the main filler region 67. In some embodiments, the hinge region 55 comprises less than 25% of the expandable material that is the main filler region 67. In some embodiments, the hinge region 55 comprises less than 10% of the expandable material that is the main filler region 67. In some embodiments, the hinge region 55 has no expandable material. In some embodiments, the hinge region 55 is a longitudinal strip of a certain width. However, the hinge region 55 may have one or more other suitable shapes.

[0075] In some embodiments, the first and second overlapping layers include a third wall portion 65, and the hinge region includes a first hinge region disposed between the first and second wall portions, and a second hinge region disposed between the second and third wall portions, such that the first and third wall portions, folded about hinges in the first and second hinge regions respectively, each overlap the second wall portion, thereby forming a first wall of the packaging container, and the first and third wall portions forming a second wall of the packaging container, the second wall overlapping the first wall and defining an interior cavity between the walls. A sealing material is arranged to seal the first wall to the third wall. In some embodiments, the first and third wall portions have longitudinal edges such that, in the folded configuration, the longitudinal edges are disposed above the second wall portions and sealed together by the sealing material. In some embodiments, the second wall portion has a lateral width between hinge lines, and the first and third wall portions cumulatively have a cumulative lateral width at least as wide as the lateral width of the second wall portion.

[0076] like Figures 4A-4C As shown, in some embodiments, the hinge region extends longitudinally, the overlapping layer includes longitudinally extending edges, and a sealing material is arranged to seal the edges together in the folded position.

[0077] In some embodiments, the first wall portion and the second wall portion each form a wall. In some embodiments, the first wall portion and the second wall portion each include a longitudinal edge, and a sealing material is arranged to fix the wall portion along the longitudinal edges of the first wall portion and the second wall portion.

[0078] like Figure 5-6 As shown, a plurality of longitudinal sealing portions 30 are configured to seal a plurality of webs 10 together. According to this embodiment, the packaging container 44 is formed by sealing a plurality of webs 10 together rather than folding a single web 10.

[0079] Once the web 10 of the packaging material is formed, the web 10 is combined in an unexpanded, high-density supply configuration to form the web raw material of the packaging material. According to some embodiments, the unexpanded, high-density supply configuration can be rolled into, for example... Figure 7 The exemplary supply roll configuration 52 is depicted. The roll configuration 52 can be a cored roll configuration or a coreless roll configuration. Another suitable high-density supply configuration is achieved by folding the web 10 into a fan-like stacked configuration with opposing creases 56, such as a fan (e.g., accordion) configuration 54 (e.g., Figure 8 (as exemplarily depicted), and / or other suitable configurations. Another suitable high-density supply configuration is a series of two or more stacked packaging units. (e.g.) Figure 8 As shown, prior to merging, the web 10 is folded into a series of pre-formed packaging containers 44. The web 100 can be in a high-density supply configuration 58 (e.g., Figure 7 As shown), the expandable wall formed by the web 100 is compressed into an unexpanded configuration. According to other embodiments, the web 10 can be a high-density packaging container configuration 60 (such as...). Figure 8 As shown), one or more expandable walls are configured as a series of pre-formed packaging containers 44 and compressed into an unexpanded high-density configuration.

[0080] refer to Figures 9A-9BA system 70 for a supply chain to convert raw materials into packaging containers is shown. A web 10 includes a first layer 12 and a second layer 14. The first layer 12 is fed in direction 72, the second layer 14 is fed in direction 74, and the first layer 12 is bonded to the second layer 14. An extension material 20 is applied to the first layer 12 using an extension material applicator 64, and one or more sealing materials 66 are applied to the first layer 12 using a sealing material applicator 68. After the extension material 20 and sealing material 66 are applied, the first layer 12 and the second layer 14 are bonded. This bonding may include applying pressure using a pressure applicator 76 configured to apply pressure to the first layer 12 and the second layer 14.

[0081] After the first layer 12 and the second layer 14 are bonded, one or more external sealing materials are applied to the outside of the web 10 to form one or more external sealing portions 30, 32 (in... Figure 2 (Shown in more detail below). One or more longitudinal seals 30 are applied to the outer longitudinal edge 34 of the web 10 using a longitudinal seal applicator 78, and one or more transverse seals 32, 36 are applied between one or more longitudinal seals 30 using a transverse seal applicator 80. The web 10 is then fed in direction 42 through a folding device 82 that folds the web 10.

[0082] The folding device 82 includes a folding mechanism 84 (e.g., a folding rod 84). A tension mechanism 86 (e.g., a wheel 87) applies tension to the web 10, causing the folding rod 84 to fold the web 10 along its shape. The folding mechanism 84 may be a V-shaped folding rod or other suitable folding shape. For example, in some alternative embodiments, the folding mechanism 84 includes multiple bends.

[0083] The web 10 is folded along the folding edge 40. The folding device 82 includes a flattening mechanism 88 configured to flatten the web 10 once folded by the folding mechanism 84. The flattening mechanism 88 is a flattening bar configured to apply pressure to the web 10 and flatten it. The web 10 is then sealed along one or more longitudinal seals 30 using a sealing device. The flattening mechanism function 88 can serve as the sealing device. In other embodiments, the system 70 may alternatively incorporate a separate sealing device. The sealing device is configured to apply heat, pressure, and / or activate one or more longitudinal seals 30 in other suitable ways.

[0084] System 70 includes a cutting device 90. The cutting device 90 is configured to form one or more weakened regions 50 and openings 62 in the web 10. The one or more weakened regions 50 are configured to facilitate the separation of the web 10 into one or more individual packaging elements (e.g., one or more packaging containers). The openings 62 are configured to provide access to the cavities 46 of each of the one or more packaging containers 44. The openings 62 may be slits. In other embodiments, the openings 62 are not completely cut by the cutting device 90, but are configured to be torn. It should be noted that the one or more weakened regions 50 and / or openings 62 may be formed before or after the web 10 is joined. The cutting device 90 includes an upper pressure roller 92 and a lower pressure roller 94. The upper pressure roller 92 includes a series of teeth 96 configured to pierce the web 10, forming weakened regions 50 transverse to the longitudinal edges of the folded web 10. The lower pressure roller 94 may include a rigid surface, an elastomer, or other suitable material. In some embodiments, the cutting device includes one or more blades, a thermal cutter, and / or other suitable components for cutting one or more portions of the web 10.

[0085] The web 10 includes one or more weakened regions 50 extending laterally (e.g., generally perpendicularly) to the longitudinal direction at one or more longitudinal edges. In other embodiments, the weakened regions 50 may alternatively be located elsewhere along the lateral direction of the web 10. The weakened regions 50 may be provided by perforation, notching, or other suitable techniques for weakening material at desired locations to facilitate separation of individual envelope segments. The weakened regions 50 may be provided between each pair of adjacent packaging container structures 44, thereby allowing separation of individual packaging container structures 44. The weakened regions 50 may be disposed within the periphery of the lateral seals 32, 36. The weakened regions 50 may extend through two layers 12, 14, or alternatively through one layer. The web 10 may include one or more slits configured to facilitate separation of adjacent packaging container structures 44.

[0086] To prevent the expansion material 20 from escaping from the packaging container structure 44 (especially when a chemical reaction is used to expand the expansion material), the lateral seal 18 of the first layer 12 and the lateral seal 24 of the second layer 14 can be positioned such that they are contained in the area before and after the weak zone 50. The web 10 may include one or more slits at its longitudinal edges to aid in separation.

[0087] System 70 includes a merging device 98 configured to merge webs 10 into unextended high-density configurations, such as a roll configuration 52, a fan-shaped stack configuration 54, and / or other suitable configurations. The merging device 98 is configured to bend, roll up, and / or otherwise change the shape of the webs 10 into the merged unextended high-density configuration.

[0088] It should be noted that the expansion material 20 and / or sealing material 66 may be applied to the first layer 12 and / or the second layer 14. It should also be noted that the web 10 may include suitable expansion wall configurations and materials as described herein, such as the inflatable expansion material shown and described herein in web 120.

[0089] like Figure 10 As shown, the web 10 includes a first bag wall 100 and a second bag wall 102. The wall includes a wall cavity 47 in which the extended material 20 is received. The first bag wall 100 may include a cut 104 configured to provide access to the inner cavity 46 of the packaging container structure 44, while the second bag wall 102 includes a weakening region 50 configured to separate the top 106 of one packaging container structure 44 from the bottom 108 of a subsequent packaging container structure 44. The opening 46 is sealed along a seal 36. In some embodiments, the seal 36 includes a sealing material different from that of the seal 32. In some embodiments, when the seal 32 is formed, the seal 36 remains unformed until an object is placed within the inner cavity.

[0090] like Figure 11 As shown, the cutting mechanism 90 is configured to cut through the first bag wall 100, while the teeth 96 of the cutting mechanism 90 perforate the second bag wall 102. A notch 110 exists between the teeth 96, configured to form a perforation 50. The cutting mechanism 90 forms an opening 62, configured to provide access to the inner cavity 46 of the bag. In some embodiments, the cutting mechanism 90 is configured to form the opening 62 above the weakened region 50. In some embodiments, the cutting mechanism 90 is configured to form the opening 62 adjacent to the weakened region 50. In some embodiments, the cutting mechanism 90 is configured to form the opening 62 displaced by a distance 35 from the weakened region 50, thereby forming a gap 38 between the opening 62 and the weakened region 50 (e.g., ...). Figure 2 (As shown).

[0091] refer to Figure 12A-12D The web 10 can be a multi-layer inflatable film web 120 used for inflatable protective packaging. For example... Figure 12A-12DAs shown, some embodiments of this disclosure particularly relate to methods, systems, products, apparatuses, and / or devices typically associated with flexible structures that form inflatable chambers. Flexible structures for inflatable protective packaging are provided, such as multilayer inflatable film webs 120. The inflatable web 120 includes a first web film layer 122. The inflatable web 120 also includes a first longitudinal edge 124 and a second longitudinal edge 126. The inflatable web 120 includes a second web film layer 128 having a first longitudinal edge 130 and a second longitudinal edge 132. The longitudinal edges 124, 126, 130, and 132 extend along a longitudinal direction 134 of the web 120. The longitudinal direction of the web 120 can be the direction in which the web 120 is advanced into a processing machine. The longitudinal direction 134 can also be the direction in which the web 120 is fed into the processing machine or the direction in which the product structure is wound onto a storage roll after processing. The longitudinal direction 134 can be longitudinally upstream or longitudinally downstream. The longitudinal upstream direction 136 is the longitudinal direction opposite to the direction in which the web 120 moves through the processing machine. The longitudinal downstream direction is the direction substantially the same as the direction in which the web 120 moves through the processing machine. Typically, the longitudinal direction 134 corresponds to the longest dimension of the web film layers 122, 128. The second layer 128 is aligned to overlap and may extend substantially together with the first layer 122 (e.g., ...). Figure 12A As shown), that is, at least the corresponding first longitudinal edges 124, 130 are aligned with each other and / or the second longitudinal edges 126, 132 are aligned with each other.

[0092] In some embodiments, layers 122, 128 may partially overlap with inflatable regions in the overlapping region. Layers 122, 128 may be combined to define a first longitudinal edge 140 and a second longitudinal edge 142 of film 120. This can be achieved using separate sheets or folded onto a single sheet. A longitudinal seal 144 may be formed at the first longitudinal edge 140, and a longitudinal seal 146 may be formed at the second longitudinal edge 142. For example, first longitudinal edges 124, 130 may be joined together to form the first longitudinal edge 140 of film 120, and second longitudinal edges 126, 132 may be joined together to form the second longitudinal edge 142 of film 120. The joining of the respective edges forms an hermetically tight seal at the first and second longitudinal edges 140, 142 of film 120.

[0093] In some embodiments, the thin film layer 136 can be sealed onto the layer 122, thereby sandwiching the layer 122 between the layers 128 and 136, as... Figure 12CAs shown. This provides additional stiffness to the structure. The thin film layer 136 includes a first longitudinal edge 148 and a second longitudinal edge 150. The first longitudinal edges 124, 130, and 148 can be joined together to form the first longitudinal edge 140 of the thin film 120, and the second longitudinal edges 126, 132, and 150 can be joined together to form the second longitudinal edge 142 of the thin film 120. The joining of the respective edges forms an hermetically sealed area at the first and second longitudinal edges 140, 142 of the thin film 120. Although in some embodiments, the first longitudinal edge 140 is not necessarily closed, it may remain open to form an inflatable region 152, thereby allowing fluid to be injected from the side. However, in other embodiments, the first longitudinal edge 140 is closed, thereby forming a closed inflatable region 152, for example, in which a channel for inserting a nozzle is inserted.

[0094] Web 120 can be formed from any of a variety of web materials known to those skilled in the art. Such web materials may include ethylene vinyl acetate (EVA), metallocene, polyethylene resins (e.g., low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and high-density polyethylene (HDPE)), paper, metals, and mixtures thereof. Other materials and structures may be used. The disclosed web 120 can be rolled onto a hollow tube, folded in a folding fan box, or folded into another desired form for storage and transport.

[0095] Different layers (e.g., 122, 128, and / or 136) can be connected by different seals across their extended regions. The seals may simply connect the film layers, or they may further define or allow features to function. For example, layers 122, 128 can be connected together by seal 154. Additionally or alternatively, according to various embodiments, one or more fluid receiving cavities 156 are defined within the boundary formed by seal 154. Seal 154 can seal layers 122, 128 with one or more unsealed areas (e.g., fluid receiving cavities 156). In some embodiments, the unsealed portion may also include channels 158 and / or swollen regions 152. Seal 154 can extend from a first longitudinal edge 140 to a second longitudinal edge 142, thereby defining various fluid receiving cavities 156 between the film layers. In some embodiments, such as Figure 12AAs shown, the sealing portion 154 has a generally transverse orientation. The web 120 includes a series of transverse sealing portions 154 arranged in a transverse direction along a longitudinal range of the web 120. The transverse direction is a direction extending at an angle to the longitudinal direction of the web 120. In some embodiments, the transverse direction is substantially perpendicular to the longitudinal direction. However, in other embodiments, the transverse direction may be at a non-perpendicular angle greater than zero degrees and less than 90 degrees to the longitudinal direction. In some embodiments, the sealing portion 154 may abut against the sealing portion 160 of the connecting edge 142. In some embodiments, the sealing portion 154 may abut against the sealing portion 162 defining the inflation region 152. A second end 162 of the sealing portion 154 may be spaced apart from the first longitudinal edge 140 by a transverse dimension D. The distance between the first end 160 and the second end 162 defines the transverse width of the transverse sealing portion 154.

[0096] Implementation in Figure 12A Each lateral seal 154 is substantially straight and extends substantially perpendicular to the second longitudinal edge 142 (e.g., laterally through the film 120). However, it should be understood that other arrangements of the lateral seals 154 are also feasible. It is conceivable that the lateral seals 154 may extend along their entire sealing area; however, it is also conceivable that the lateral seals may seal around the periphery with their middle portion unsealed, thereby forming a pouch-like structure in their middle portion. It is also conceivable that the lateral seals 154 may be sealed with longitudinal seals 144 near the second end 162. In other embodiments, a pair of substantially linear seals may be arranged on either side of the separation area.

[0097] The transverse sealing portion 154 and the sealing longitudinal edges 140, 142 (which may be the same continuous sealing portion in some embodiments) can be formed by any of a variety of techniques known to those skilled in the art. These techniques include, but are not limited to, adhesion, friction, welding, fusion, heat sealing, laser sealing, and ultrasonic welding.

[0098] The inflatable web 120 may include a fluid receiving cavity 156. In various embodiments, the fluid receiving cavity 156 may be both inflatable and compressible (e.g., Figure 12A-12DIn other embodiments, the fluid-receiving cavity 156 can be filled with fluid upon inflation, with no mechanism to compress the cavity except to break it up. In some embodiments, the fluid-receiving cavity can be an inflatable / compressible cavity 166 having an inflation port 168. In some embodiments, the fluid-receiving cavity 156 can be a large cavity extending across and / or around multiple features (e.g., inflatable cavities). In some embodiments, the fluid-receiving cavity can be a completely isolated cavity that is filled with fluid upon formation without any compression mechanism. These different cavities can be used individually to form an inflatable web or can be used in any suitable combination to form a web. Some of these different embodiments are discussed in more detail below. According to various embodiments, the various cavities contain fluid such that the respective web film layers defining the cavity remain separated from each other at the location of the cavity to provide cushioning. Suitable fluids can be gases, such as air, carbon dioxide, nitrogen, or other suitable gases. The fluid can also be a liquid or a gel.

[0099] The web 120 may include an inflatable region 152 (e.g., a closed or open channel adapted to receive injected fluid). In one example, the inflatable region 152 is as follows: Figure 12A-12D The example illustrates a longitudinally inflatable channel. A longitudinally inflatable region 152 is disposed between the second end 162 of the transverse seal 154 and the first longitudinal edge 140 of the film 120. The longitudinally inflatable region 152 may extend longitudinally along the longitudinal edge 140, and an inflatable opening 174 may be disposed at at least one end of the longitudinally inflatable region 152. The longitudinally inflatable region 152 has a transverse width. In a preferred embodiment, the transverse width is substantially the same as the distance between the first longitudinal edge 140 and the second end 162, which is the transverse dimension. However, it should be understood that other suitable transverse width dimensions may be used in other configurations.

[0100] In some embodiments, the fluid receiving cavity is an inflatable / contractable cavity 166 having an inflatable port 168. For example, Figure 12B It shows Figure 12A The cross-section of the inflatable sheet material includes two layers that are layered and comprise multiple sub-chambers. According to various embodiments, cavity 166 is formed by an unsealed location between two layers of material (e.g., 128 and 122). According to various embodiments, in the formation of cavity 166, at least one thin film layer (e.g., 122) includes an extension 176. In some embodiments, the inflatable cavities include separate fluid-containing chambers that are separate from and configured to be sealed separately from other cavities.

[0101] According to various embodiments, the extension 176 may define a bounded three-dimensional shape suitable for containing fluid. The extension 176 may also be foldable for packaging in a denser configuration than in an inflated form. This bounded volume may be partially defined by complex surfaces protruding from at least one layer (e.g., 122). For example, when laid flat, the layers typically define a flat form. While it is understood that layers 122, 128 are flexible and thus can define complex surfaces within their extension when they are bent, folded, or otherwise deformed, they can also generally conform to a flat surface within their extension when laid flat, thus generally defining a flat surface. Even when defining a flat surface, the extension 176 protrudes from this generally flat surface as a separate complex surface, thereby forming multiple separate, distinct cushioning structures within the layer. Complex surfaces forming separate cushioning structures can be presented even without internal air pressure. For example, as... Figure 12B and 12C As shown, extension 176 protrudes from layer 122 away from layer 128. In embodiments where layer 122 includes one or more extensions 176, the layer defines a forming layer 122. In embodiments where layer 128 includes one or more extensions, layer 128 additionally or alternatively defines a forming layer. In embodiments where layer 128 does not include one or more extensions, layer 128 defines a base layer 128. As described below, in various embodiments, layer 128 may be a base layer, but in other embodiments, layer 128 may be a forming layer. For clarity relative to the examples shown in the various figures, layer 128 may be provided and referred to as a base layer, while layer 122 may be referred to as a forming layer. However, these are presented merely as examples, and those skilled in the art will understand that both layers may be forming layers, or alternatively, one layer may be a forming layer.

[0102] According to various embodiments, the structure of the extension 176 can be defined by three-dimensional plastic deformation in the surface of the material layer (e.g., 122), thereby forming a complex surface. As used herein, plastic deformation refers to permanent deformation that occurs when a material is subjected to tensile, compressive, bending, or torsional stresses exceeding its yield strength, resulting in elongation, compression, bending, flexing, or twisting, leaving permanent structural deformation of the material. When the layer is initially manufactured, it can have a generally uniform cross-section. The extension 176 is a separate plastic deformation of the material forming a separate complex surface. In various examples, the plastic deformation is non-uniform throughout the extension 176, thus forming a complex curve. In one particular example, some portions of the forming layer (e.g., 122) are plastically stretched away from the generally extended surface of the film and discrete locations defining the complex surface. In such embodiments, at the structural level, the material of the layer will behave as a polymer undergoing plastic deformation, plastic stretching, thinning, and / or permanent physical alteration (meaning the structure will not naturally revert to its previous shape or size) at the location of each extension 176. The base layer (e.g., 128) closes the generally open side of the concave side of the extension 176, forming a cavity or sub-chamber 178. A plurality of interconnected sub-chambers 178 can be defined as follows: Figure 12B and 12C The chamber shown is 156.

[0103] In an alternative embodiment, multiple plastic layers are positioned flat on top of each other. A sealing pattern can be applied to the unstretched portions of the layers to define a fluid chamber. In some embodiments, the plastic layers are unstretched plastic layers. Multiple unstretched, flat plastic film layers are stacked on top of each other, and a sealing pattern is applied to define an inflatable chamber. In this embodiment, portions of the layers surrounding the fluid chamber are unstretched. In some embodiments, the entire film layer is unstretched. Inflatable web materials with suitable configurations known in the art can be used. For example, the material shown in U.S. Patent Publication No. 2019 / 0291907.

[0104] In various embodiments, the extension 176 has a periphery 180 that defines an opening to be closed by a base layer (e.g., 128). The area of ​​this opening is smaller than the surface area of ​​the surface forming the extension 176 protruding away from the base layer (e.g., 128). In embodiments where the extension 176 is formed by plastic stretching, the material previously covering the opening area is plastically stretched to form the extension 176.

[0105] According to various other embodiments, the structure of the extension 176 can be formed by other suitable structures that define complex surfaces protruding from the layer. For example, the extension 176 can be molded in place to prevent plastic deformation of the layer material. In another example, the extension 176 may include a second capping structure that is heat-sealed or otherwise bonded to the surface of the layer. Although not necessarily enumerated herein, other suitable structures that define complex surfaces protruding from the layer are also contemplated herein, as will be understood by those skilled in the art.

[0106] According to various embodiments, the extension 176 may protrude from one layer, thus defining a single direction of cavity protrusion, or it may protrude from two layers, thus defining protrusion from two surfaces of the web 120. In one example, the extension 176 protrudes from a forming layer (e.g., 122) rather than a base layer (e.g., 128). In such examples, the base layer (e.g., 128) forms part of a bounded cavity but is defined by its natural shape in response to fluid pressure, while the extension of the forming layer (e.g., 122) takes on the applied shape of the extension 176. Therefore, in the absence of internal fluid pressure, the base layer (e.g., 128) does not necessarily protrude at the location of the cavity. Even in the presence of internal fluid pressure, the protrusion of the base layer (e.g., 128) in the same region of the web 120 is minimal or significantly less than the protrusion of the cavity 156. In another example, the extension is defined in two layers but in non-opposite positions. In other words, in the position where the extension is located in one layer, the extension is not located in a directly opposite position to the other layer. In another example, each extension 176 independently defines two layers at the same or similar locations, such that the chamber protrudes in both directions at the overlapping locations of the layers. Although shown as circular by way of example, it should be understood that the extension 176 may include a variety of suitable shapes and sizes. For example, the extension 176 may be rectangular, triangular-elliptical, elliptical, etc.

[0107] In some embodiments, the protective packaging includes a pre-formed, inflated shell (see, for example, bubble wrap material). In some embodiments, the extension 176 is closed in a manner that allows the cavity 166 to be inflatable and / or compressible after the web 120 is manufactured. For example, each cavity 166 may include an inflation port 168. A channel 158 may be connected to the inflation port 168 or a similar suitable structure for adding fluid to or removing fluid from the cavity 166 after it has been formed. In some embodiments, the various cavities 166 are also compressible and inflatable after the web 120 is manufactured. This contrasts with conventional protective packaging (e.g., bubble wrap material), which traps fluid in bubbles during manufacturing and cannot be compressed after the material is manufactured without breaking the bubbles (in which case the bubbles cannot be refilled). According to various aspects of this disclosure, the cavities 166 can be inflatable after the web is manufactured and after the cavities 166 of the web have been compressed. This can be accomplished by injecting air into the inflatable port 168 of the cavity 166. In some embodiments, the various cavities can be sealed once they are finally inflated, thereby maintaining the inflated configuration.

[0108] According to various embodiments, a plurality of cavities 166 are inflatable and compressible, together forming a chamber 156. For example, a sub-chamber 178 may have an inflatable port 168 interconnected with another sub-chamber 178 via a channel 158. This set of interconnected sub-chambers 178 together forms a chamber 156 having a common inflatable channel 158 adapted to distribute fluid to each sub-chamber 178 through their respective ports 168. Figure 12A As shown, the common inflatable channel 158 can be a channel extending in series (i.e., daisy-chain) between a row of chambers 156. In another embodiment, the common inflatable channel can be a manifold extending parallel to each chamber 156 (e.g., in some embodiments, isolated chambers are fed parallel to adjacent chambers). According to various embodiments, the channel 158 can extend from the inflatable region 152. In some embodiments, the web 120 includes a plurality of chamber channels 158, each chamber channel 158 pointing to a separate chamber 156. For example, as... Figure 12A As shown, multiple channels 158 extend from the inflation region 152. In this example, each channel extends laterally across the material from the longitudinal inflation region 152. Additionally, different sets of chambers are provided along the longitudinal length of the web 120.

[0109] The chamber 156 is sufficiently confined to retain fluid after sealing. In some embodiments, the chamber 156 may be inflatable after formation. In some embodiments, the chamber 156 may be contractile after formation. In some embodiments, even after a final seal is applied to the chamber, fluid may be transferred between sub-chambers to prevent additional fluid from being added to the chamber. In some embodiments, the chamber 156 is also contractile after formation and before sealing.

[0110] like Figure 12B As shown in the example, the web 120 may include transversely arranged chambers 156 formed by a plurality of sub-chambers 178, each chamber being connected to an inflatable region 152. In this way, fluid injected into the inflatable region 152 can enter the inflation port 168 of each sub-chamber 178 through the channel 158, thereby filling the sub-chambers 178 and the chambers 156.

[0111] According to various embodiments, each portion of the web 120 (i.e., between the weakened regions discussed herein) may have a relatively small number of large chambers. For example, each portion may have one large chamber. In another example, each portion may have 2-5 chambers. In yet another example, each portion may have 5-20 chambers. In other embodiments, the web 120 may have a relatively large number of extensions, which may or may not form chambers. These numerous extensions are referred to as caps. The caps may be plastically deformed extensions as discussed above. For example, more than 20 plastically deformed extensions per portion may be referred to as caps.

[0112] In some embodiments, the cavity 166 may be individually inflatable. For example, each cavity 166 may include a separate inflation port leading to the outside of the web 120. Such inflation port may include a one-way valve, a sealable port, a mechanically closed port, etc.

[0113] According to various embodiments, when the web 120 is inflatable and ready for use as protective packaging, one or more of the inflatable port 168, channel 158, or inflatable region 152 can be sealed to at least partially isolate the cavity 156 and / or sub-cavity 166. Once the final seal is applied, embodiments without valves are no longer sealable or compressible. At this point, fluid forced into one or more of the inflatable region 152, expansion port 168, channel 158, sub-cavity 166, or cavity 156 can be forced out and then forced back in. This allows material to be inflated and then compressed to a more concentrated state for easy transfer and transport. After being transferred and when ready for use as protective packaging, the web 120 can be inflatable and given a final seal.

[0114] According to various embodiments, the inflatable channel 158 may be an extended protrusion in the formed plate layer 122. These extended channels may be fabricated similarly to the extension 176 described above. For example, these channels may have a structure including a plastically deformable forming layer 122. In other embodiments, the channel 158 may be formed from an unsealed area between the forming film 122 and the base layer 128. Fluid can then pass between the unsealed layers 122 and 128. A seal may then restrict the sides of the channel to guide fluid from one cavity to the next. In various embodiments, the channel is significantly smaller than the chamber 156 and / or the extension 176.

[0115] In some embodiments, the fluid-containing cavity may be an isolation cavity that is filled with fluid during formation. This isolation cavity has no inflatable port, so the fluid can only be released upon rupture. Similar to the inflatable cavity 166 discussed above, the isolation cavity is formed by an extension 176 similar to those discussed above. However, as a distinction, the isolation cavities are filled during formation because they have no inflatable ports or connecting channels, and therefore cannot be inflated or deflated unless ruptured. In this embodiment, layers 122 and 128 seal each other around the entire circumference of the cavity without any inflatable ports or channels.

[0116] In some embodiments, the isolation cavities may include intracavitary channels. These cavities are filled during formation. They do not have external expansion ports but may include channels extending between sub-cavities, allowing fluid contained therein to move back and forth within the communicating sub-cavities.

[0117] However, these isolation cavities can be surrounded by inflatable cavities. The isolation cavities can be defined by a sealing portion 154, thus forming a periphery around them, wherein the isolation cavities are not sealed. For example, as described above, layers 122 and 128 can be sealed together to define an isolation cavity or inflatable cavity 178. A third layer 136 can also be provided. The third layer 136 is a third layer because it can be attached to the base layer 128 and the forming layer 122. In various examples, the forming layer 122 is sandwiched between the third layer 136 and the base layer 128. In such embodiments, the third layer 136 is sealed to the forming layer 122. In one example, the sealing portion is located on the outer surface of the extension portion 176. In a more specific example, the sealing portion is located on the furthest protrusion of the outer surface of the extension portion 176. The third layer 136 is also sealed to the forming layer 122 transversely across the layer at periodic locations along the length via a transverse sealing portion. Similar sealing portions can be applied to other examples of the web shown herein (e.g., Figure 12AThe lateral seal may be located at the location of the laterally weakened region. Also as described above, the third layer 136 may have longitudinal seals along edges 144 and 146 and a final seal along the inflatable region. Each of these external seals (e.g., 144 and 146) encloses the area surrounding the extension 176. Seal 192 holds the third layer 136 to the outer surface of the extension 176. In the embodiments discussed below, the volume between layers 122 and 136 and within the seals is an auxiliary cavity. Here, the cavity is shown as containing fluid. In some examples, the fluid may be open to the atmosphere (see, for example...). Figure 12D The fluid can also be sealed. For example, the fluid here may have been trapped when layer 136 was sealed to layer 122. In some embodiments, the volume is passively inflatable (e.g., Figure 12D In some embodiments, the volume is actively inflatable. Therefore, the auxiliary cavity can form a separable, inflatable, and / or separable, sealable chamber from the cavity defined by the extension portion 176.

[0118] In various embodiments, the web 120 includes one or more separation weakening regions 164. Separation regions 164 facilitate the separation of two adjacent web portions, such as separated chamber assemblies 156. These regions can be separated, for example, by hand or with the aid of tools or machines, tearing the web 120. Separation regions 164 can facilitate partial or complete separation of adjacent inflatable chambers 156, or both. Figure 12A As shown in the schematic diagram, the separation region 164 is located between chambers 156. In this way, chambers 156 can be easily separated from each other. Figure 12A In some embodiments, a thin lateral seal 154 is arranged adjacent to the separation region 164 on either side. Although illustrated adjacent to the seal 154, it should be understood that the separation region 164 may also extend through the seal 154 or through unattached layers 122, 128, 136 (as included in certain embodiments), for example through various inflatable cavities and the layers defining them. In various embodiments, a weakening line may be used to separate the region.

[0119] For example, Figure 12A A schematic diagram of an inflatable web 120 is shown, comprising multiple transverse chambers 156 and inflatable sub-chambers 178, which repeat longitudinally along the length of the inflatable web 120. Each sub-chamber 178 within each chamber 156 is connected by a channel 158. The channel 158 is also connected to an inflatable region 152 for inflating or deflating the chambers 156. Figure 12B Based on Figure 12A A schematic cross-sectional view of an inflatable web 120 according to a specific embodiment. In some examples, such as... Figure 12A The fabric shown can be made using only the following: Figure 12BLayers 122 and 128 shown are made of, Figure 12A The web shown can also be made with more layers, such as layers 122, 128, and 136. Since these are merely examples, it can be understood that any suitable number of layers can be used to form web 120. Figure 12B The cross section (which is along) Figure 12A As shown in the cross-section (section line 1-1), the extension portion 176 is formed in layer 122 and sealed to the base layer 128 that forms sub-chamber 178. The connected sub-chamber forms chamber 156. Figure 12C Based on Figure 12A A cross-sectional schematic diagram of an inflatable web 120 according to another specific embodiment. Here, web 120 includes layers 122, 128, and 136. Again, these are merely examples, and it can be understood that any suitable number of layers can be used to form web 120. Figure 12C The cross section (which is along) Figure 12A As shown in the cross-section (section line 1-1), an extension 176 is formed in layer 122 and sealed to the base layer 128 forming sub-chamber 178. The communicating sub-chamber forms chamber 156. A third layer 136 can be sealed to forming layer 122 at the peak of the inflatable region 176. The cavity defined therebetween is an inflatable auxiliary cavity. An inflatable region 152 is formed between layers 122 and 128. Fluid can be injected into chamber 156 via the inflatable region 152.

[0120] For example, in another embodiment, the third layer 136 includes openings near its edges 148, 144. These openings allow air to pass through layer 136 to the volume between layer 136 and forming layer 122. Therefore, when chamber 156 is inflated, the volume can be filled with fluid (e.g., atmosphere). This restricts layer 136 from being bonded to layer 122 via a vacuum therebetween.

[0121] Figure 12D Another example of a passively inflatable cavity is illustrated. In this embodiment, the inflatable web 120 includes an inflatable sub-chamber and a perforated third layer 136. The perforation 196 passes through the third layer 136 but not through the other layers. The perforation 196 allows air to pass through layer 136 to reach the volume between layer 136 and forming layer 122. Therefore, when chamber 156 inflates, the volume can be filled with fluid (e.g., atmosphere). This restricts layer 136 from being vacuum-bonded to layer 122 therebetween.

[0122] For example, alternatively, the web 120 may include chambers 156 positioned diagonally relative to the inflatable region 152. This diagonal orientation can improve the compactness of the chambers after initial formation. In some embodiments, the chambers 156 terminate before traversing the web 120. Premature termination of the chambers creates gaps, allowing the application of weakening regions to form separation regions 164. In some embodiments, the inflatable web 120 may alternatively have staggered-oriented inflatable sub-chambers 178. Here, each sub-chamber 178 is connected to the next adjacent sub-chamber 178 via a channel 158. Each distinct channel exits the sub-chamber 178 at opposite angles. This leaves a staggered pattern of sub-chambers 178, forming a sawtooth chamber design. This allows more sub-chambers 178 to be packed into a single web. In some embodiments, the chambers 156 have a linear lateral orientation, where the channels 158 communicate with the central inflatable region. One set of channels exits the inflatable region in one direction while another set exits in the opposite direction. This allows chamber 156 to extend from the inflated area in two directions.

[0123] In some alternative embodiments, the inflatable web 120 includes an isolation cavity. This cavity is surrounded by an auxiliary cavity. The inflation region directs fluid into the auxiliary cavity. A final seal along the inflation region seals the fluid into the auxiliary cavity. In some embodiments, the web 120 includes one or more segmented seals that seal the auxiliary cavity to the weakening line 164. Thus, segments of the web 120 can be torn at the weakening line 164 without rupturing the auxiliary cavity.

[0124] It should be understood that while the third layer 136 can be used to form auxiliary cavities, it can additionally or alternatively be used to reinforce the web 120, making it more rigid. The additional layer increases stiffness by forming an I-beam-like structure. This means that while the volume of the web 120 can be an inflated sub-cavity or similar cavity, their dispersion on the surface does not necessarily increase stiffness. However, a thin film layer is present at the top and bottom of these cavity structures, which forms an I-beam that increases stiffness. This can be achieved by increasing the moment of inertia. As not otherwise noted herein, the cavity between the third layer 136 and the forming layer 122 can be inflated after the forming layer is formed. The cavity can be inflated before, after, or simultaneously with the inflating of the chamber defined by the forming layer 122.

[0125] Once the web 10 is assembled, it is fed through a protective packaging machine as shown in Figures 13-14 and 17A-17B.

[0126] Using a bagging machine / bagging device 200 as shown in Figures 13-14 and Figures 17A-17B A protective packaging machine, such as the bagging machine / bagging device 300 shown, performs one or more steps to form a series of bags.

[0127] As shown in Figures 13-14, the bagging machine 200 is fed with a web 10 that has been pre-folded and / or sealed to include a pre-formed bag structure. In other embodiments, for example in Figures 17A-17B In this process, the bagging machine 300 is configured to receive an unfolded or unsealed web 10 and form the web 10 into one or more packaging container structures 44.

[0128] If the web 10 includes an inflatable material, the bagging machine can inflate the inflatable material before setting the seal. If the web 10 includes an extension material 20, the bagging machine can extend the extension material before, during, or after setting the seal by applying heat or other suitable means.

[0129] according to Figures 13A-13B In the embodiment shown, the bagging machine 200 can be configured to receive the web 10 of the pre-formed packaging container structure 44 and to open the opening 62 in each bag structure to access the cavity 46 of each bag structure 44.

[0130] exist Figure 13A In one embodiment, the bagging machine 200 includes a plurality of fingers 202 and / or telescopic protrusions 204 configured to open the bag opening 62, thereby enabling one or more products / objects / etc. to be inserted into the inner cavity 46.

[0131] The web 10 is fed into the bagging machine 200 in an unexpanded, high-density configuration. On the supply side of the bagging machine 200, the web 10 may be in a fan-shaped supply configuration 54 and / or other suitable configurations, such as a roll configuration 52. The bagging machine 200 includes a bag conveyor comprising one or more mechanisms and / or devices for moving the web downstream from the supply source through the bagging machine 200. The bag conveyor includes a bag mover configured to move the web 10 along the bagging device 200.

[0132] The bagging machine 200 includes an expansion device 206. If the web 10 includes an expansion material 20, the expansion device 206 may include a heating element, a heating coil, a hot air applicator, a radio frequency radiation generator, an ultraviolet light applicator, a chemical reaction applicator, a pressure mechanism, or other suitable means for expanding the expansion material. Alternatively or additionally, if the web 10 includes one or more inflatable chambers, the expansion device 206 may include an inflatable device configured to inject fluid to expand and fill the fluid chambers (e.g., such as...). Figure 16A -I shown). The fluid can be air or other suitable fluid. In some embodiments, the expandable element of the web 10 includes a one-way valve to retain fluid in the chamber. In some embodiments, the inflatable chamber requires a longitudinal seal (see, for example...). Figure 16A-I). In some embodiments, such as Figures 13A-13B As shown, the expansion mechanism 206 is positioned and configured to expand the expandable element before the product is inserted into the cavity 46. In other embodiments, the expansion mechanism 206 is positioned and configured to expand the expandable element after the product is inserted into the cavity 1105. In still other embodiments, such as... Figure 14A As shown in -C, the expansion mechanism 206 is positioned and configured to expand the expandable element during insertion of the product into the cavity 46.

[0133] like Figure 13A As shown, the extension device 206 is positioned upstream of the bagging mechanism 208 to convey the web 10 to the bagging mechanism 208. The bagging mechanism 208 is configured to seal the bag structure and (act as a separator) separate the bag structure from subsequent bag structures, thereby forming individual bags.

[0134] In other embodiments, the extending device 206 is positioned at or downstream of the bagging mechanism 208 to extend the wall of the web 10 at other points during the bag-making process. In some embodiments, such as Figure 13B As shown in Figures 1 and 14, one or more images and / or one or more data / information can be printed onto the web 10 using the printing assembly 210.

[0135] like Figure 13B As shown, the expansion mechanism 206 is configured to expand the expansion element before the bag opening 62 is opened to insert one or more products. In other embodiments, as shown in FIG14, the expansion mechanism 206 is configured to expand the expansion element at the same time as or after the bag opening 62 is opened to insert one or more products.

[0136] The web 10 includes one or more weakened regions 50 and one or more openings 62, which are applied prior to the sealing process. In other embodiments, one or more weakened regions 50 and / or one or more openings 62 are applied during or after the sealing process. The weakened regions 50 are configured to be disrupted to separate one packaging container from a subsequent packaging container. The openings 62 are configured and positioned to provide access to the interior cavity 46 of the packaging container configuration 44 and can be opened by mechanical fingers 202 and / or suction cups 212. Pressurized air can be used to assist in opening the openings 62 in the packaging container configuration 44.

[0137] Finger 202 is configured to clamp a portion of the packaging container opening 62, providing a further securing means of opening the packaging container at the opening 62 and holding it in place. The bagging machine 200 may include a blower 214 configured to apply air pressure to the opening 62 to aid in opening the packaging container. The opening 62 may include a bag-shaped seal. Once the product is inserted, the bag seal may include an adhesive for sealing the opening 62. Other forms of sealing the opening 62, such as heat sealing, may be implemented additionally or alternatively. Once the opening 62 is closed and sealed, the weakened area 50 can be destroyed by a suitable means (e.g., flipping over the next packaging container, cutting, melting, or other suitable methods).

[0138] Each packaging container 44 in the web 10 can be separated using a tensile force applied to each packaging container 44, tearing a weakened region 50 located between each bag in a series of bags, or using one or more cutting blades configured to form a slit along the seam connecting two packaging containers 44 in a series of packaging containers 44. In some embodiments, each bag in the series of bags is separated using concentrated heat configured to melt a portion of the seam connecting two packaging containers 44 in the series of packaging containers 44.

[0139] The operating procedure can begin from the front of the web 10 and continue until the opening 62 is positioned above the sealing area 216, as follows. Figure 16A As shown, the opening faces vertically and longitudinally along the length of the packaging unit. The amount of fabric 10 being advanced can be programmed into the controller program based on the bag length to properly position the opening 62 (i.e., the system can advance the same number of fabric 10 each time), or alternatively, computer vision (e.g., an optical sensor) can be used at the inlet 218 to pause the advancement of the fabric 10 when the weakened area 50 appears in the appropriate position at the bag inlet 218. The bagging machine 200 may include a control panel 220 configured to control one or more functions of the bagging machine 200 (e.g., ...). Figure 13A As shown). Figure 16B As shown, the procedure continues from the initial opening of the packaging container 44. The bagging machine 200 may use a vacuum-assisted device (e.g., a suction cup 212) (and / or an air knife or other suitable device) to slightly enlarge the opening 62 to allow fingers (e.g., rear fingers 204 and front movable finger 202) to be inserted into the opening 62. In this and preceding stages, the rear film control element (e.g., finger 204) may be in a disengaged position relative to the web 10 (e.g., positioned outside the periphery of the web 10 in this example). Figure 16C As shown, after the initial opening 62 is set, the front film control element (e.g., the finger 202 rotates downward into the opening 62 to grip the front side of the packaging container 44) is unfolded. At this time, the rear film control element (finger 204) is also unfolded, and as shown... Figure 16DAs shown, the rear finger 204 moves toward the centerline of the inlet 218, as indicated by arrow 222. In some embodiments, the rear finger 204 is translated inward to a position where the rear finger 204 is substantially aligned with the front finger (or telescopic protrusion) 202, at which point they can extend laterally into the opening 62. In other embodiments, the fingers 204 may be advanced to different lateral positions (e.g., to a position where they are closer together than the front finger 202) before they extend into the packaging container 44. For example, in the case of the telescopic finger 204, air pressure can be used to deploy the telescopic portion into the packaging container 44 (e.g., by releasing pressurized air onto the telescopic portion 224 of the finger 204).

[0140] like Figure 16E As shown, the insertion of the finger 204 into the opening 62 (along direction 226) can occur simultaneously with (or slightly earlier than) the outward extension of the finger 204 (along direction 226), and simultaneously pushes the front finger 202 away from the bag entrance 218 (along the opening direction 240), causing the opening 62 to become tautly engaged between the rear finger 204 and the front finger 202, as... Figure 16F As shown. The front finger-shaped member 202 can be mounted on the movable structure 203 (e.g., Figure 13A As shown in --13B and 14, the movable structure 203 is configured to allow the front finger 202 to move. In some embodiments, a suction cup 212 is mounted on the movable structure 203.

[0141] like Figure 16F As shown, up to this point, a portion of the rear perforation near the longitudinal edge of the web 10 may be torn or has been torn. However, at least a portion of the rear perforation (e.g., up to 50%, typically more than 50%) remains intact to keep the packaging container 44 attached to the web 10 until product loading is complete. At this point, the packaging container 44 is ready to be filled into the cavity 46, which can be performed by a human operator or a robotic operator controlled by the bagging machine 200. In the case of a human operator, the control system 220 may display instructions (e.g., instructions for loading the packaging container 44) to the user and / or may wait for operator input, which may be provided by the user placing his or her hand on a handheld workstation or contact associated with the safety shield 228 to indicate that the product has been provided in the packaging container 44 and the operator's hand has left the bagging area 230. In the case of a robotic operator, a signal indicating the completion of the product loading procedure can be generated in the background and transmitted to the controller to automatically initiate the bag closing and sealing phase of the process.

[0142] like Figure 16GAs shown, during bag closure, the pressure plate 232 advances along the bag closure direction 234, while the front finger 202 holds the front side of the opening 62 in the closed position. The bagging machine 200 may also include a pad 236 (e.g., Figure 16A (As shown) (e.g., a foam pad), configured to apply pressure to the bag to remove air from the packaging container 44. Simultaneously, the rear fingers 204 translate outwards (along direction 222) to widen the bag opening 62 and thereby flatten the top of the packaging container 44, preparing for the sealing operation. During the sealing operation, the pressure plate 232 presses against the sealing area 216, causing the buffer on the pressure plate 232 to elastically deform, thereby applying an appropriate amount of pressure to the front and rear sides of the bag to achieve the sealing operation.

[0143] like Figure 16H As shown, when the pressure plate 232 engages the sealing region 216 and / or the sealing operation is completed, the front finger 202 disengages from the opening 62 (e.g., pivots to the open position), while the rear finger 204 remains engaged with the outer edge of the opening 62. This keeps the opening 62 flat during the sealing operation. In some embodiments, the pressure plate 232 includes a sealing mechanism 233, such as a heating element (e.g., Figures 13A-13B (as shown in Figure 14). After the sealing operation is completed, the weakened region 50 is torn, for example by means of... Figure 16I Reverse the web 10 as shown (along direction 238) to separate the filled and sealed packaging container 44 and release the sealed packaging container 44 toward the bag outlet.

[0144] like Figures 17A-17B As shown, the bagging machine 300 is configured to convert and seal the web 10 into one or more finished packaging containers 302. The web 10 is fed into the bagging machine 300 in an unextended high-density configuration via a bag conveyor. The web 10 may have a roll structure 52. The bag conveyor may include a bag mover configured to move the web 10 along the bagging device 300. In other embodiments, the web 10 may be one or more other unextended high-density configurations, such as a fan-shaped configuration.

[0145] Once fed into the bagging machine 300, the web 10 is extended by an extension device 206 configured to extend the extendable elements of the web 10. According to some embodiments, the web 10 includes one or more hinge lines 55, which include a segment 304 of the web 10 that is not extended, or the web 10 includes little or no extension material, thereby forming a natural hinge to facilitate folding of the web 10. In some embodiments, the lines of the web 10 may be without extension material 20 to form a natural hinge line or region that is more flexible than other areas where extension material 20 is extended. In some embodiments, pressure is applied to the extension material 20 during or after extension, thereby forming a hinge line or region 55 at segment 304 that is more flexible than other areas.

[0146] The expanded web 10 continues to be fed through a folding device / bag folder 306, which is configured to fold the web 10 such that the longitudinal edges of the web 10 contact each other. The folding device 306 may include one or more folding rods 308 configured to fold the web 10 into a C-shaped fold structure. The folding device 306 may fold the web 10 along a hinge region 55 or at one or more other segments. The folding device 306 may also include a crossbar 310 configured to align the web 10 such that the folded web 10 forms an inner cavity 312. Once folded, a series of retaining mechanisms (e.g., fingers 314) hold the open web 10 open, allowing one or more products to be placed into the inner cavity 312. Figure 17B In this embodiment, the web is positioned vertically, while the product is placed horizontally into the cavity 312, with the opening transverse to the longitudinal direction of the web. In other embodiments, the web may be placed horizontally or at another suitable angle (e.g., with the opening of the cavity 312 facing upwards).

[0147] Once the product is placed into the inner cavity 312, the web 10 is fed to a sealing mechanism 316, which is configured to seal the longitudinal and transverse seals of the web 10. The sealing mechanism 316 may be configured to apply heat, pressure, and / or other suitable methods to establish the seals. In some embodiments, the sealing mechanism 316 is configured to pull the web through the bagging machine 300 for sealing. Once sealed, the web 10 is converted into a formed and sealed bag 302. According to some embodiments, the bagging machine 300 includes a separating mechanism 318 configured to separate the bag 44 from the web 10. In some embodiments, the separating mechanism 318 is configured to pull the completed bag 320, thereby tearing the completed bag 320 from the subsequent bag along the weakened region 50. In some embodiments, the separating mechanism 318 is configured to separate the bag 320 by blade cutting or heating. In some embodiments, the separating mechanism 318 may be combined with other suitable separating devices. According to some embodiments, the separating mechanism 318 is configured to hold the bag 302 in place so that the sealing mechanism 316 can seal subsequent bags.

[0148] like Figure 15 As shown, some embodiments of the packaging material expansion device 206, such as the expansion and bagging device described above, are associated with an inflatable web comprising one or more inflatable chambers / cavities 156 that must be sealed after inflation (e.g., as shown in the diagram). Figure 12A This can be used with the web 120 shown or other suitable inflatable webs. The extension device 206 includes an inflatable nozzle 170, which delivers fluid, for example, via an inflatable channel 152 to the inflatable chamber 156 of the web 120. In this embodiment, the nozzle 170 has a longitudinally elongated portion 138 configured to be received in the circumferentially closed inflatable channel 152 to guide the inflatable channel 152 thereon and into the sealing mechanism 188.

[0149] Fluid can be supplied along path 172 from a suitable source (e.g., an air compressor, fan, or compressed air supply). In other embodiments, other suitable fluids may be used. In this embodiment, the fluid exits the nozzle 170 via a radial opening 184, which in this embodiment is generally laterally aligned with the inflatable channel 152 and the inflatable chamber 156. For embodiments using a circumferentially closed inflatable channel, a cutting device, such as a blade 186, is disposed near the nozzle 170 to cut open the inflatable channel 152 to allow the web 120 to exit the nozzle 170 as it moves downstream from the nozzle. In embodiments using a circumferentially open inflatable region, a cutting device is typically not required.

[0150] Once filled, the sealing mechanism 188 is configured to seal the fluid chamber / cavity 156, forming a longitudinal seal 190 that seals the fluid connection channel 158 between the inflatable channel 152 and the inflatable chamber 156, typically extending longitudinally through the transverse seal 171 defining the inflatable chamber 156. In this embodiment, the sealing mechanism 188 includes an upper roller 194 and a lower roller 198 configured to apply pressure and heat sufficient to longitudinally heat-seal the web 10 together as it passes through in direction 42. In embodiments using different types of seals, a suitable alternative sealing mechanism is selected. Other known inflatable and sealing devices can be used in expansion and bagging devices, such as the mechanism disclosed in U.S. Patent Publication No. 2019 / 0291907.

[0151] like Figure 18 As shown, expander 408 expands the opening of packaging container 402 to allow product 400 to be inserted into packaging container 402. Once product 400 is inserted into packaging container 402, packaging container 402 is sealed and exits bagging mechanism 404 and is conveyed via conveyor mechanism 406 for transport. Bagging mechanism 404 can be a bagging mechanism as described herein, such as bagging mechanism 200.

[0152] according to Figure 19 In method 500, in step 505, a web of packaging material is generated. The web may comprise one or more layers. The web may include a first layer, a second layer, and one or more expandable elements coupled to the first and / or second layers. The one or more layers may comprise paper (e.g., paperboard, kraft paper, fiberboard, pulp paper, recycled paper, newsprint, and coated paper (e.g., paper coated with wax, plastic, waterproof, and / or stain-resistant materials), plastic, cellulose, foil, polyethylene, or synthetic materials, biodegradable materials, and / or other suitable materials having suitable thickness, weight, and dimensions. These layers may include recyclable materials (e.g., recyclable paper). Expandable elements may be positioned between the first and second layers. In application, the expandable elements are in an unexpanded configuration. Referring to the flowchart, method 500 is described using suitable apparatus and systems described herein. Suitable apparatus and systems include, but are not limited to, examples such as, but not limited to, […]. Figures 9A-9B System 70 Figures 13A-13B And 14 bagging machines 200, Figures 17A-17B 300 bagging machine.

[0153] The expandable element may include one or more inflatable chambers. The one or more inflatable chambers may include one or more cavities configured to be filled with fluid, such as air or other suitable fluid.

[0154] The expandable element may include one or more expandable materials in an unexpanded configuration. One or more expandable materials may include emulsion-based polymers, including starch, vinyl acetate, polyvinyl acetate, polyvinyl alcohol, one or more polyvinyl acetate copolymers, one or more polyvinyl alcohol copolymers, dextrin-stabilized polyvinyl acetate, one or more polyvinyl alcohol acetate copolymers, one or more vinyl acetate copolymers, one or more ethylene copolymers, vinyl acrylic acid, styrene acrylic acid, acrylic acid, styrene-butyl rubber, polyurethane, biodegradable materials (e.g., cellulose), and / or other suitable expandable materials.

[0155] In some embodiments, the extended material may include a polyolefin-based adhesive or polyolefin dispersion. The polyolefin dispersion may include polyethylene and / or polypropylene, and / or other suitable polyolefin dispersions. Suitable polyolefin dispersions may include, for example, HYPOD from Dow Chemical. TM Or other suitable polyolefin dispersions. The extended material can be applied to the web as a continuous layer or in a pattern. The pattern can be configured such that when the layers are pressed together, the extended material extends to form a continuous layer.

[0156] In some embodiments, the spreading material may include an adhesive and thermally spreading microspheres combined with the adhesive to produce a thermally spreading adhesive. The microspheres may be mixed with the adhesive before being applied to the web, or layered on top of the adhesive after it has been applied to the web, allowing the microspheres to be forced into the adhesive as the layers are pressed together. For example, the spreading material may include an adhesive applied to a first layer, with the microspheres loosely applied to the surface of the adhesive. Microspheres not adhering to the adhesive can then be collected and discarded or reused, and when a second layer is applied on top of the first layer, the microspheres adhering to the adhesive are pressed into the adhesive, clamping the adhesive and microspheres between the first and second layers.

[0157] Generating the web may include forming one or more weakened regions along the web. The one or more weakened regions may be positioned along a first layer and / or a second layer and configured to allow one packaging element to be separated from another packaging element. The one or more weakened regions may include one or more notches, slits, perforations, dimpled marks, one or more combinations of the aforementioned weakened regions, and / or other suitable forms of weakened regions on one or more longitudinal edges of the web.

[0158] In step 510, the web is converted into a series of bag structures prior to merging. This conversion may include applying one or more seals to the outer surface of the web and folding and sealing the web to form the bag structures. The bag structures include an inner cavity configured to receive one or more goods, products, etc. The conversion may include forming an opening configured to provide access to the inner cavity. According to some embodiments, expandable elements are positioned against the opening. According to other embodiments, expandable elements are spaced apart from the opening. According to some embodiments, the web does not form bag structures prior to merging.

[0159] Once the web is formed, it is merged into an unexpanded high-density configuration in step 515. The unexpanded high-density configuration can be a roll configuration, a fan-shaped configuration, and / or other suitable high-density configuration. It should be noted that in some embodiments, the one or more weakened regions may be formed after the web is merged into the unexpanded high-density configuration.

[0160] After being merged into an unexpanded high-density configuration, the web is fed into the bagging mechanism in step 520.

[0161] In step 525, one or more expandable walls are expanded by extending expandable elements. Expansion is performed using one or more expansion devices of the bagging mechanism. Expansion occurs after the web is merged into an unexpanded high-density configuration. According to some embodiments, the expansion device is positioned along the bagging device such that it is configured to expand the expansion material before the sealer seals the closure opening. According to some embodiments, the expansion device is positioned along the bagging device such that it is configured to expand the expansion material while the sealer seals the closure opening. According to some embodiments, the expansion device is positioned along the bagging device such that it is configured to expand the expansion material after the sealer seals the closure opening.

[0162] The expandable element may include one or more inflatable chambers, wherein expanding one or more expandable walls includes filling one or more cavities with a suitable fluid. According to some embodiments, the one or more cavities are refillable.

[0163] The scalable element may include one or more scalable materials, and extending one or more scalable walls involves applying a catalyst to convert one or more scalable materials from a high-density configuration to a low-density configuration. The catalyst may be a thermal, chemical, physical, or other suitable catalyst.

[0164] If the web is pre-formed into a series of bag structures, the bagging mechanism positions the web in step 530 to access the cavity of each bag structure, allowing one or more products to be loaded into the cavity. Positioning the web may include opening the bag structure at the opening using one or more techniques and / or other suitable methods described herein. The web may include a sealable strip of material positioned along the opening. The sealable strip of material is configured to seal the opening after one or more products have been loaded into the cavity. In step 540, the opening is sealed using the sealable strip of material. The sealable strip of material may be any suitable sealable material described herein, such as a heat-sealable material, a pressure-sealing material, an adhesive material, a cohesive material, and / or other suitable sealable material.

[0165] If the web is not pre-formed into a series of bag structures, then in step 540, the bagging mechanism is configured to convert the web into one or more bag structures using the techniques described herein and / or other suitable methods. The conversion may include folding the web such that its longitudinal edges meet, and in step 545, forming one or more seals to seal the longitudinal edges together. The conversion may also include forming one or more seals transverse to the one or more longitudinal seals.

[0166] At step 550, after or simultaneously with sealing the opening or sealing the longitudinal edges together, the bagging mechanism separates a bag from the subsequent bag structure of the web, and at step 555, the package is sent for transport.

[0167] The methods and apparatus described herein can provide one or more pressure-bonded seals for packaging elements. The use of pressure-bonded seals can reduce or eliminate the number of heat-sealed parts used to form mailing bags.

[0168] Examples of components, including but not limited to nozzles, blowers, sealing assemblies, and drive mechanisms, and various components or related systems thereof, can be constructed, positioned, and operated as disclosed in the various embodiments described in incorporated references such as U.S. Patent Nos. 8,061,110 and 8,128,770, U.S. Patent Publication No. 2014 / 0261752, and U.S. Patent Publication No. 2011 / 0172072, each of which is incorporated herein by reference. Each embodiment discussed herein can be incorporated and used with various sealing devices and / or other inflatable and sealing devices of the incorporated references. For example, suitable mechanisms discussed herein and / or in the incorporated references can be used for the inflation and sealing of webs 10 and 120. Examples of one or more inflatable openings or ports may include a one-way valve such as that disclosed in U.S. Patent No. 7,926,507, which is also incorporated herein by reference in its entirety. Examples of bagging machines (e.g.) Figures 13A-13BThe bagging machine 200 of 14 can also be further utilized according to U.S. Patent Publication No. 2020 / 0115082, filed October 11, 2019, which is also incorporated herein by reference. For example, to provide... Figure 1 , 3 Examples of suitable systems and methods for the expandable materials shown in 4, 6, 7, 9A-9B, and 10 are disclosed in U.S. Provisional Patent Application No. 62 / 706,111, filed July 31, 2020, entitled “METHOD OF MAKING AN EXPANDABLE WEB,” the contents of which are incorporated herein by reference in their entirety. Examples of expandable materials and expandable material compositions can be found in U.S. Patent Publication No. 2019 / 0062028, filed September 11, 2018.

[0169] This disclosure is not limited to the specific examples described herein, which are intended to illustrate various aspects. Many modifications and examples can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatus within the scope of this disclosure, in addition to those methods and apparatuses enumerated herein, will be apparent to those skilled in the art based on the foregoing description. Such modifications and examples are intended to fall within the scope of the appended claims. This disclosure is limited only by the terms of the appended claims and by the fact that such claims are used to describe specific examples and are not intended to be limiting.

[0170] Regarding the use of virtually any plural and / or singular terms in this document, those skilled in the art can translate from plural to singular and / or from singular to plural depending on the context and / or application. For clarity, various singular / plural substitutions may be explicitly described herein.

[0171] While various aspects and examples have been disclosed herein, other aspects and examples will be apparent to those skilled in the art. The various aspects and examples disclosed herein are for illustrative purposes and not for limitation; the true scope and spirit are indicated by the appended claims.

Claims

1. A bagging device, comprising: A bag transferor configured to transfer a packaging material web defining a series of bags detachable from the packaging material web, each bag having a first wall and a second wall surrounding an inner cavity configured to contain an object for transport, the first wall comprising an extension material having an expandable configuration and expandable to provide padding to the first wall to protect the object contained within the inner cavity, wherein the packaging material web is fed into the bagging device via the bag transferor in an unexpanded, high-density configuration when the extension material is in the expandable configuration, and wherein the bag transferor comprises: A bag opener configured to engage one or both of the first wall and the second wall, and to form an opening between the first wall and the second wall, so that the object can be received into the cavity through the opening. A sealer configured to seal the opening between the first and second walls leading to the inner cavity, thereby retaining the object within the inner cavity. A separator, configured to separate the bags from adjacent bags in the series of bags after the opening has been sealed; and An extension device is configured to apply an extension condition to the packaging material associated with each bag prior to separation from adjacent bags in the series of bags, the extension condition being configured to cause the extension material to extend from an expandable configuration to an extended configuration.

2. The bagging apparatus according to claim 1, wherein the sealer is a heat sealer configured to form a heat seal between the first wall and the second wall.

3. The bagging apparatus of claim 1, wherein the bag opener includes a blower configured to apply air pressure directed toward the opening.

4. The bagging apparatus of claim 1, wherein the bag opener comprises a plurality of fingers for extending into the opening and maintaining the opening in an open configuration.

5. The bagging apparatus of claim 1, wherein the bag opener comprises one or more suction devices configured to apply a suction force to at least one of the walls, the suction devices being configured to open the opening.

6. The bagging apparatus of claim 1 further includes a bag mover configured to move bags to the extension device and the bag transferor.

7. The bagging apparatus of claim 6, wherein the expanding device is positioned along the bagging apparatus such that the expanding device is configured to expand the expanding material before the sealer seals the opening.

8. The bagging apparatus of claim 6, wherein the expanding device is positioned along the bagging apparatus such that the expanding device is configured to expand the expanding material while the sealer seals the opening.

9. The bagging apparatus of claim 6, wherein the expanding device is positioned along the bagging apparatus such that the expanding device is configured to expand the expanding material after the sealer seals the opening.

10. The bagging device of claim 1, wherein the extension material is expandable into an extension configuration to provide thermal insulation to the first wall for thermal insulation of an object contained in the inner cavity.

11. The bagging apparatus of claim 1, wherein the expanding device is configured to apply expanding conditions to the packaging material associated with each bag before sealing the opening.

12. The bagging apparatus of claim 1, wherein the expanding device is configured to apply expanding conditions to the packaging material associated with each bag prior to forming the opening.

13. The bagging apparatus of claim 1, wherein the expanding device is configured to direct microwave or RF energy to the packaging material, causing the expanding material to rise to an expanding temperature sufficient to expand the expanding material into an expanding configuration.

14. A bagging system comprising the bagging apparatus and packaging material web as claimed in claim 1.

15. A bagging device, comprising: A bag transferor configured to transfer a packaging material web defining a series of bags detachable from the packaging material web, each bag having a first wall and a second wall surrounding an inner cavity configured to contain an object for transport, the first wall comprising an extension material having an expandable configuration and expandable to provide padding to the first wall to protect the object contained within the inner cavity, wherein the packaging material web is fed into the bagging device via the bag transferor in an unexpanded, high-density configuration when the extension material is in the expandable configuration, and wherein the bag transferor comprises: A sealer configured to seal an opening between the first and second walls leading to the inner cavity, thereby retaining the object within the inner cavity. A separator, configured to separate the bags from adjacent bags in the series of bags after the opening has been sealed; and A bag folder configured to fold packaging material over itself to provide a first and second wall; and An expansion device configured to apply expansion conditions to packaging material associated with each bag prior to separation from adjacent bags in the series of bags, the expansion conditions being configured to cause expandable material to expand from the expandable configuration to the expanded configuration, the expansion conditions being configured to reduce the density of the expandable material and cause the expandable material to expand into the expanded configuration.

16. The bagging apparatus of claim 15, wherein the separator includes a cutter configured to cut the packaging material.

17. The bagging apparatus of claim 15, wherein the expanding device is configured to heat air and direct the heated air to the packaging material, thereby raising the temperature of the expanding material to an expanding temperature sufficient to expand the expanding material into an expanding configuration.

18. The bagging apparatus of claim 15, wherein the sealer is a heat sealer configured to form a heat seal between the first wall and the second wall.

19. The bagging apparatus of claim 15, wherein the expanding device is positioned along the bagging apparatus such that the expanding device is configured to expand the expanding material before the sealer seals the opening.

20. The bagging apparatus of claim 15, wherein the expanding device is positioned along the bagging apparatus such that the expanding device is configured to expand the expanding material while the sealer seals the opening.

21. The bagging apparatus of claim 15, wherein the expanding device is positioned along the bagging apparatus such that the expanding device is configured to expand the expanding material after the sealer seals the opening.

22. The bagging device of claim 15, wherein the extension material is expandable into an extension configuration to provide thermal insulation to the first wall for thermal insulation of an object contained in the inner cavity.

23. The bagging apparatus of claim 15, wherein the expanding device is configured to apply expanding conditions to the packaging material associated with each bag before sealing the opening.

24. The bagging apparatus of claim 15, wherein the expanding device is configured to apply expanding conditions to the packaging material associated with each bag prior to forming the opening.

25. The bagging apparatus of claim 15, wherein the expanding device is configured to direct microwave or RF energy to the packaging material, causing the expanding material to rise to an expanding temperature sufficient to expand the expanding material into an expanding configuration.

26. A bagging system comprising the bagging apparatus and packaging material web as described in claim 15.

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