Method for forming a protective packaging web and an inflatable web

Abstract

Disclosed is a protective packaging web comprising: a flexible, expandable web having an inlet and including an inflatable chamber configured to receive fluid through the inlet and seal the fluid therein, the flexible, expandable web configured such that when the inflatable chamber is inflated, the expandable web structure has a first contoured outer surface including a plurality of peaks and valleys, the peaks defining a first imaginary interface connecting the plurality of peaks, and a flexible first outer layer attached to the peaks of the first contoured surface and spaced apart from the valleys, such that when the chamber is inflated, the first outer layer stretches along the first imaginary interface and bridges the valleys of the first contoured surface, such that when the chamber is inflated, the attached first outer layer and the expandable web cooperate to form a frame structure having a bending stiffness significantly improved over that experienced by the expandable web structure without the first outer layer attached.

Description

Technical Field

[0001] This application claims the benefit of U.S. Provisional Application No. 62 / 946,826, filed Dec. 11, 2019, the disclosure of which is hereby incorporated by reference in its entirety.

[0002] The present invention relates to an inflatable cushioning material for packaging and shipping. More specifically, it relates to a package having plastically deformed chambers that are inflatable after the material is formed.

Background Art

[0003] A conventional type of protective packaging is known as bubble wrap. Bubble wrap is made of a flexible plastic film with caps that are vacuum formed. This film is sealed to another flat and flexible plastic film at the outer periphery of the caps, isolating and sealing the cavities formed by the caps and capturing air therein to provide a low-density protective packaging sheet. Some bubble wraps are manufactured by sealing a flat and flexible plastic film over the caps of other flat films, often referred to as "third web bubbles" and are used, for example, to manufacture padded envelopes. However, bubble wrap, once manufactured, has to be transported to the site in its bulky low-density configuration, making the transportation to the packaging site volumetrically inefficient.

Summary of the Invention

[0004] According to one aspect of the present disclosure, a protective packaging web is provided. The web is a flexible and expandable web having an inlet and including an expandable chamber configured to receive fluid from the inlet and seal the fluid therein. When the expandable chamber expands, the expandable web structure has an outer surface with a first undulation including a plurality of ridges and valleys, and the ridges are configured to define a first virtual tangent plane connecting the plurality of ridges. The web further includes a flexible first outer layer attached to the ridges of the first undulating surface and spaced from the valleys, and when the chamber expands, the first outer layer extends along the first virtual tangent plane, bridging the valleys of the first undulating surface. When the chamber expands, the attached first outer layer and the expandable web cooperate to form a frame structure having a bending stiffness significantly improved over the bending stiffness of the expandable web structure where the first outer layer is not attached.

[0005] In certain embodiments, the expandable web structure can include first and second overlapping chamber layers having a seal pattern therebetween that provides an undulating surface when the expandable chamber expands.

[0006] In certain embodiments, the first chamber layer defines a first undulating surface, and the second chamber layer is a second outer layer that cooperates with the first outer layer and the first chamber layer to provide the frame structure.

[0007] In certain embodiments, the second surface is configured to define a second undulating outer surface when the expandable chamber expands on a major side opposite the first undulating surface.

[0008] In certain embodiments, the web further includes a second flexible outer layer attached to the crests in a first undulating surface having a plurality of crests and troughs and spaced from the troughs, the crests of the second undulating surface defining a second virtual contact surface in contact with the plurality of crests, and when the inflatable chamber expands, the second outer layer extends along the second virtual contact surface, bridging the troughs of the second undulating surface, thereby cooperating to increase the bending stiffness of the frame structure.

[0009] In certain embodiments, the distance along the first undulating surface between the crests to which the first outer layer is attached is greater than the distance along the first outer layer between the crests to which the first outer layer is attached.

[0010] In certain embodiments, the protective packaging web having an inflated inflatable chamber has a thick plate configuration that is naturally biased to maintain a flat configuration in which the first and second outer layers extend substantially flat.

[0011] In certain embodiments, the crests include a plurality of crests arranged in a 2D pattern on the first undulating surface.

[0012] In certain embodiments, the inflatable chamber includes a plurality of protruding structures, each of the protruding structures including a base perimeter surrounding an open base region and an extension surface protruding from a flat portion defined by a flexible and inflatable web in a substantially flat state, the protruding structure having a surface area larger than the open base region, forming a series of cavities, and each of the plurality of protruding structures including an inflation port that allows the plurality of cavities to expand through the inflation port.

[0013] In certain embodiments, the surface of the protruding structure is at least partially formed in a plastically stretched portion of the flexible and inflatable web.

[0014] In certain embodiments, each of the inflatable chambers extends along the flexible and inflatable web at an angle that is not perpendicular to the longitudinal edge of the flexible and inflatable web.

[0015] In certain embodiments, a flexible and expandable web and a flexible first outer layer form therebetween a second flexible chamber having an inlet for receiving fluid from the inlet and sealing the fluid therein.

[0016] In certain embodiments, the web further includes one or more discharge elements between the flexible and expandable web and the flexible first outer layer and is configured to remove fluid from one or more second expandable chambers.

[0017] In certain embodiments, the flexible first outer layer extends along the length of the flexible and expandable web.

[0018] In certain embodiments, the web further has a channel connected to the inlet, the channel forming a flow path is formed within the flexible and expandable web, the inlet allows fluid to flow out of and back into the expandable chamber, and the expandable chamber can be folded in a substantially unexpanded state and then returned to an expanded state.

[0019] In certain embodiments, the expandable chamber is configured to receive adjacent longitudinal seals that close the inlet and prevent the expandable chamber from expanding or contracting.

[0020] In certain embodiments, the flexible first outer layer is configured to be attached to the flexible and expandable web via a heat seal.

[0021] In certain embodiments, the web further includes a heat-resistant material attached to one or more of the flexible first outer layer and the flexible and expandable web, and the heat-resistant material prevents the first outer layer from being heat-sealed to the flexible and expandable web at the position where the heat-resistant material is disposed between the flexible first outer layer and the flexible and expandable web.

[0022] According to another aspect of the present disclosure, a method for forming an inflatable web is provided. The method includes a flexible and inflatable web including an inflatable chamber having an inlet configured to receive fluid and seal the fluid therein, an inflated inflatable chamber, and an inflatable web structure having a first corrugated outer surface including a plurality of ridges and valleys, the web structure defining a virtual tangent plane connecting the plurality of ridges; providing, when the inflatable chamber is inflated and the inlet is not yet sealed, the first outer layer is separated from the valleys, the first outer layer extends along the virtual tangent plane, bridging the valleys of the first corrugated surface, and when the chamber is inflated, the attached first outer layer and the inflatable web together form a frame structure and have a significantly increased bending stiffness compared to the bending stiffness resulting from the inflatable web structure without the first outer layer attached; attaching a flexible first outer layer to the ridges of the first corrugated surface.

[0023] In certain embodiments, the method further includes holding the inlet in at least a partially closed state to retain the fluid within the inflated chamber, and while the inlet is held closed, the first flexible layer is attached to the ridges.

[0024] In certain embodiments, the inlet is held closed by pinching.

[0025] In certain embodiments, the flexible outer layer is attached to the ridges by heat sealing.

[0026] In certain embodiments, the method further includes applying a heat-resistant material to one or more of the flexible first outer layer and the flexible and inflatable web, the heat-resistant material preventing the first outer layer from being heat-sealed to the flexible and inflatable web at a position where the heat-resistant material is disposed between the flexible first outer layer and the flexible and inflatable web.

[0027] In certain embodiments, the corrugated surface is at least partially formed by a plastically stretched portion of the first film layer.

Brief Description of the Drawings

[0028] The foregoing features and other features of the present disclosure will become more fully apparent from the following description and the appended claims in connection with the accompanying drawings. It should be understood that these drawings illustrate only some examples and thus should not be regarded as limiting the scope. The present disclosure will be described more specifically and in detail by using the accompanying drawings.

[0029]

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[0030] Each of the above reference drawings is arranged in accordance with at least some embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0031] The present invention relates to a flexible structure that can be expanded and used as a cushioning or protective material for packaging and transportation. In the following detailed description, it will be described with reference to the drawings forming a part thereof. In the drawings, like reference numerals typically identify like components unless the context indicates otherwise. The exemplary embodiments described in the detailed description, the drawings, and the claims are not limiting. Other examples can be utilized and other changes can be made without departing from the spirit or scope of the subject matter presented herein. Aspects of the present disclosure are generally described herein and can be arranged, substituted, combined, separated, and designed in a variety of different configurations as shown in the drawings, and all of which are readily understood to be implicitly contemplated herein.

[0032] Some aspects of the present disclosure are directed to packaging elements formed from packaging materials. Some packaging elements formed from packaging materials include pads and sheets that include a single wall. Some packaging elements formed from packaging materials include packaging containers, which include a plurality of walls that enclose an internal cavity for storing one or more products. Some packaging containers include bags and envelopes, such as those of a shipper, and can be assembled and then filled with items to be shipped.

[0033] Some embodiments of the present disclosure include expandable walls. Some expandable walls include walls that can be expanded, which are in a non-expanded form and can be expanded later. Some expandable walls include walls that are already in an expanded form. An expandable wall may include one or more expandable chambers. Some expandable chambers include expandable chambers configured to receive a fluid, such as air or other suitable gas or non-gaseous fluid. Some expandable chambers include expanded fluid chambers. An expanded fluid chamber can include, for example, a pre-formed chamber (e.g., a vacuum-formed bubble).

[0034] The various seals described herein include an adhesive material. The adhesive includes an adhesive element. Each adhesive element includes an adhesive or sticky material to provide an adhesive or sticky surface. Combinations of adhesive and sticky surfaces can be used. The adhesive element can be applied directly to the exposed surface of the material by a suitable known method, or can be applied on a tape, such as a double-sided tape, or by other suitable methods. In some embodiments, the adhesive material includes polyethylene.

[0035] As used herein, an adhesive attachment element is preferably made from a material that adheres to other types of surfaces such as are commonly found in the vicinity of protective packaging, such as plastic, paper, or metal. An adhesive can adhere to opposing surfaces without relying on opposing surfaces having the same or complementary materials in order to effect a bond formation between the two surfaces by adhesion. Examples of suitable adhesives include liquid adhesives and pressure sensitive adhesives. A pressure sensitive adhesive can be selected to adhere after the application of a slight initial external pressure in order to create a bond. Examples of these include aqueous, acrylic, pressure sensitive adhesives similar to those applied to packaging tape, which material holds two surfaces together by surface contact only, often with a slight initial external pressure. Examples include dry adhesives, which typically do not require activation by water, solvent, or heat and adhere well to many different surfaces. Pressure sensitive adhesives that are aggressive and / or permanently tacky can be selected at room temperature. The application and use of pressure sensitive adhesives can be automated. When used in assembly, the use of pressure sensitive adhesives that do not require setup or long cure times can save time compared to using typical liquid adhesives. Bonding is preferably done immediately with a pressure sensitive adhesive and can continue without interruption of the manufacturing procedure, thereby saving significant time and labor.

[0036] The adhesive material of the adhesive element adheres one surface to the opposing surface by contacting the same or complementary adhesive material to form a bond between the two surfaces. The adhesives that adhere to each other are not sufficiently adhesive to adhere to other materials (e.g., the other surface of a protective packaging material without an adhesive element, the surface of a container, the surface of a product being transported, etc.), or in some cases, adhere very weakly compared to the bond formed by their adhering to each other. The adhesive can be a pressure-sensitive adhesive that requires pressure to activate the bond. Examples of suitable adhesive materials for making the adhesive element include natural and synthetic latex-based adhesives. The adhesive material is applied as a liquid to a suitable portion of the protective packaging material in some embodiments and in other known forms in other embodiments. Some types of adhesives, such as those made of latex, can be mixed with water without additional adhesive and bond to the non-adhesive portions of the protective packaging material, remaining adhered to the exposed surface of the applied protective packaging material when dry. In some embodiments, the adhesive material can be mixed with an adhesive that is often applied as a liquid onto the protective packaging material. The adhesive can be selected such that after applying the mixture of the adhesive and the adhesive to the protective packaging material (e.g., on a film layer), the adhesive evaporates and remains bonded to the non-adhesive protective packaging material (e.g., on a film or paper layer). One way to apply the liquid is by spraying, but brushing or other suitable methods can be used. Also, other suitable methods for applying the adhesive to the surface of the non-adhesive material can alternatively be used.

[0037] Referring to FIGS. 1A - 1D, a flexible structure for an inflatable protective package, such as a multi - layer inflatable web or protective packaging web 100, is provided. The inflatable web 100 includes formed web film layers or layers 105. The inflatable web 100 also includes a first longitudinal edge 102 and a second longitudinal edge 104. The inflatable web 100 includes a base web film layer or layer 107 having a first longitudinal edge 106 and a second longitudinal edge 108. The longitudinal edges 102, 104, 106, 108 extend in the longitudinal direction 103 of the inflatable web 100. The longitudinal direction of the web can be the direction in which the web 100 is advanced through a processing machine. The longitudinal direction 103 can also be the direction in which the web 100 is supplied to the processing machine, or the direction in which the finished structure is rolled onto a storage roll after processing. The longitudinal direction 103 can be longitudinal upstream or longitudinal downstream. The longitudinal upstream direction 103 is the longitudinal direction opposite to the direction of movement of the web 100 through the processing machine. The longitudinal downstream direction 111 is substantially the same direction as the direction of the web 100 through the processing machine. Generally, the longitudinal direction 103 corresponds to the longest dimension of the web film layers or layers 105, 107. The base layer 107 can be aligned to overlap the formed layer 105 (as shown in FIG. 1B) and can have a substantially the same spread, i.e., at least the respective first longitudinal ends 102, 106 are aligned with each other and / or the second longitudinal edges 104, 108 are aligned with each other. According to various embodiments, the formed layer 105 and the base layer 107 form a flexible inflatable web 154 having one or more chambers configured to be filled with a fluid. The flexible inflatable web 154 includes a first side 151 and a second side 152. According to some embodiments, the inflatable structure does not include the base layer 107, and the base layer 107 is adhered to the flexible inflatable web 154.

[0038] In some embodiments, the layer or layers 105, 107 can partially overlap an inflatable region in the overlapping region. Layers 105 and 107 are joined to define a first longitudinal edge 110 and a second longitudinal edge 112 of the web 100. This can be done using separate sheets or by folding over a single sheet. A longitudinal seal 113 can be formed at the first longitudinal edge 110, and a longitudinal seal 115 can be formed at the second longitudinal edge 112. For example, the first longitudinal edges 102, 106 can be joined together to form the first longitudinal edge 110 of the web 100, and the second longitudinal edges 104, 108 can be joined together to form the second longitudinal edge 112 of the web 100. The joining of each edge forms an airtight seal at the first and second longitudinal ends 110, 112 of the web 100.

[0039] In some embodiments, as shown in FIG. 1C (see also FIGS. 5A and 5B), a third film or third layer 109 is sealed to a layer 105 in which it is formed, thereby sandwiching the resulting layer 105 between a base layer 107 and the third layer 109. Thereby, rigidity can be added to the structure of the web 100. The third layer 109 includes a first longitudinal edge 101 and a second longitudinal edge 117. The first longitudinal edges 102, 106, and 101 can be joined together to form a first longitudinal edge 110 of the web 100, and the second longitudinal edges 104, 108, and 117 can be joined together to form a second longitudinal edge 112 of the web 100. The joining of each edge forms an airtight seal at the first longitudinal edge 110 and the second longitudinal edge 112 of the web 100. However, in some embodiments, the first longitudinal edge 110 does not necessarily have to be closed, but can be left open to form an inflatable region 114, forming the inflatable region 114 and allowing liquid to be injected from the side. However, in other embodiments, the first longitudinal edge 110 is closed to form a closed inflatable region 114 such as a channel into which a nozzle is inserted.

[0040] The web 100 can be formed from any of a variety of web materials known to those skilled in the art. Such web materials include, for example, polyethylene resins such as ethylene vinyl acetate (EVA), metallocene, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), and blends thereof. Other materials and configurations may also be used. The web 100 can be a hollow tube, wound around a solid core, folded into a box folded in a fan shape, or wound in another desired form for storage and transportation.

[0041] The various layers (e.g., 105, 107, and / or 109) can be connected via various seals throughout their extent. The seals can simply connect the film layers, or the seals can further define or enable features for functionality. For example, layers 105, 107 can be connected to each other by seal 118. Further or alternatively, according to various embodiments, one or more fluid retention cavities 120 are defined within the boundaries formed by seal 118. Seal 118 can seal layers 105, 107 along with one or more unsealed regions such as fluid retention cavity 120. In some embodiments, the unsealed portions can include inflation channels 125, inflatable regions 114, and inflation channel openings 128 between inflation channels 125 and inflatable regions 114. Seal 118 can extend from a first longitudinal edge 110 to a second longitudinal edge 112 and define various fluid retention cavities 120 between the film layers. In some embodiments as shown in FIG. 1B, seal 118 is substantially transverse. As shown in FIG. 1B, web 100 includes a series of transverse seals 118 disposed transversely along the longitudinal extent of web 100. The transverse direction is a direction that extends at an angle with respect to the longitudinal direction of web 100. In some embodiments, the transverse direction is substantially perpendicular to the longitudinal direction. However, in other embodiments, the transverse direction may not be perpendicular to the longitudinal direction at an angle greater than 0 degrees and less than 90 degrees. In some embodiments, seal 118 can be adjacent to seal 122 that connects edge 112. In some embodiments, seal 118 can be adjacent to seal 124 that defines inflatable region 114. The second end 124 of seal 118 can be spaced a transverse dimension D from the first longitudinal edge 110. The spacing between the first end 122 and the second end 124 defines the width of transverse seal 118.

[0042] Each of the lateral seals 118 embodied in FIG. 1B is substantially linear and extends substantially perpendicular to the second longitudinal edge 112 (e.g., across the membrane 100). However, it is understood that other arrangements of the lateral seals 118 are possible. It is contemplated that the lateral seal 118 can seal along its entire area, but it is also contemplated that the lateral seal may not be sealed at its central portion, forming a depression at its central portion and being sealable around the periphery. Also, it is contemplated that the lateral seal 118 can be sealed with the longitudinal seal 113 proximate to the second end 124. In other embodiments, as shown in FIG. 5A, a pair of substantially linear seals 118 can be disposed on either side of the separation region 126.

[0043] The transverse seal 118, as well as the sealed longitudinal edges 110, 112 (in some embodiments, can be the same continuous seal), can be formed from any of a variety of techniques known to those skilled in the art. Such techniques include, but are not limited to, adhesion, friction, welding, fusing, heat sealing, laser sealing, and ultrasonic welding. The expandable web 100 can include a fluid holding cavity 120. The fluid holding cavity 120 is expandable and contractible in various embodiments (e.g., FIGS. 1A - 6). In other embodiments, the fluid holding cavity 120 can be filled with fluid upon expansion without a mechanism to contract the fluid holding cavity 120, apart from destroying the fluid holding cavity 120. In some embodiments, the fluid holding cavity 120 can be an expandable / contractible cavity 135 having an inflation port 123. In some embodiments, the fluid holding cavity 120 can be a large cavity extending across and / or around some features such as cavity 133. In some embodiments, the fluid holding cavity 120 can be a completely isolated cavity 121 that is filled with fluid during formation without a contraction mechanism. These various cavities can be used separately to form the expandable web or can be used in any suitable combination to form the web. Some of these various embodiments are discussed in more detail below. According to various embodiments, the various cavities contain fluid, and each web film layer defining the cavity is held apart from the position of the cavity to provide cushioning. Suitable fluids can be air, carbon dioxide, nitrogen, or other suitable gases. The fluid can also be a liquid or a gel. The web 100 can include an expandable region 114 (e.g., a closed or open flow path suitable for receiving an injected liquid). In one example, the expandable region 114 is a longitudinally expandable channel as shown by way of example in FIGS. 1 and 2A - 2B.As shown in FIGS. 1A-1D, the expandable region 114 can be a longitudinally expandable region disposed between the second end 124 of the transverse seal 118 and the first longitudinal edge 110 of the web 100. The longitudinally expandable region 114 can extend longitudinally along the longitudinal edge 110, and the expansion opening 116 can be disposed at at least one end of the longitudinally expandable region 114. The longitudinally expandable region 114 has a width. In a preferred embodiment, the width is substantially the same distance as the lateral dimension between the first longitudinal edge 110 and the second end 124. However, it should be understood that in other configurations, other suitable width sizes can be used. In some embodiments, one or more expansion openings or ports can include a one-way valve as disclosed in U.S. Patent No. 7,926,507. U.S. Patent No. 7,926,507 is hereby incorporated by reference in its entirety.

[0044] In some embodiments, the fluid retention cavity is an expandable / contractable cavity 135 having an expansion opening 123. According to various embodiments, the cavity 135 is formed by an unsealed position between two layers of material (e.g., 107 and 105). According to various embodiments, in the formation of the cavity 135, at least one film layer (e.g., 105) includes a protruding structure 137.

[0045] According to various embodiments, the protruding structure 137 can define a three-dimensional shape with a defined boundary suitable for containing fluid. The protruding structure 137 may also be foldable for packing in a denser configuration than the inflated form. This boundary volume protrudes from at least one of the layers (e.g., 105) and can be partially defined by a complex surface that is distinct from the base webbing 141 of the layer or the valleys of the layer. For example, when laid flat, the layer generally defines a planar shape. Layers 105, 107 are flexible, and thus, as they are bent, folded, or otherwise deformed, they can define a complex surface across their extent, but when laid flat, they can generally conform to a flat surface across their extent, thereby generally being able to define a planar surface. Even when defining a planar surface, the protruding structure 137 generally protrudes away from the planar surface as a distinct complex surface, forming a plurality of individual protruding structures within the layer. The complex surface forming the individual distinct protruding structures exists even without internal air pressure. For example, as shown in FIGS. 1C, 1D, and 6, the protruding structure 137 protrudes from layer 105 away from layer 107. In embodiments where layer 105 includes one or more protruding structures 137, the layer defines the formed layer 105. In embodiments where layer 107 includes one or more protruding structures, layer 107 additionally or alternatively defines the formed layer. In embodiments where layer 107 does not include one or more protruding structures, layer 107 defines the base layer 107. As will be described below, layer 107 may be a base layer in various embodiments, but in other embodiments, layer 107 may be a formed layer. For clarity, with respect to the examples shown in the various figures, layer 107 is provided and may be referred to as the base layer, and layer 105 may be referred to as the formed layer. However, these are presented merely as examples, and those skilled in the art will understand that both layers 105, 107 may be formed layers, or alternatively, one layer may be a formed layer.

[0046] According to various embodiments, the structure of the protruding structure 137 can be defined by three-dimensional plastic deformation at the surface of a material layer (e.g., 105), forming a complex surface. As used herein, plastic deformation refers to the permanent strain that occurs when a material is subjected to tensile, compressive, bending, or torsional stress that exceeds its yield strength, causing the material to stretch, compress, buckle, bend, or twist, thereby leaving a permanent structural deformation in the material. When the layer is first manufactured, the layer can have a substantially uniform cross-section. The protruding structure 137 is a separate plastic deformation of the material forming the separate composite surface. In various examples, the plastic deformation is not uniform across the protruding structure 137 and thus forms complex curves. In certain examples, some portions of the formed layer (e.g., 105) are plastically stretched away from the generally inflated surface of the film and separate locations defining the complex surface. In such embodiments, at a structural level, the material of the layer indicates that at each location of the protruding structure 137, the polymer plastically deforms, plastically stretches, thins, and / or permanently physically changes (i.e., meaning that the structure does not naturally return to its previous shape or size). The base layer (e.g., 107) closes the generally open side on the concave surface of the protruding structure 137, forming a cavity or sub-chamber 139. The plurality of connected sub-chambers 139 can define the chamber 120, as shown in FIGS. 1C, 1D, 5C, and 6.

[0047] In various embodiments, the protruding structure 137 has a perimeter 143 that defines an opening closed by a base layer (e.g., 107). In some embodiments, the formed layer 105 and the base layer 107 are sealed along a portion of the perimeter of the protruding structure 137. Additionally or alternatively, the formed layer 105 and the base layer 107 are sealed along one or more entire perimeters of the protruding structure 137. The opening has an area 147 that is smaller than the surface area of the surface forming the protruding structure 137 that protrudes away from the base layer (e.g., 107). In embodiments where the protruding structure 137 is formed by plastic stretching, the material plastically stretched to form the protruding structure 137 is the material that pre-covers the opening area 147.

[0048] According to various other embodiments, the structure of the protruding structure 137 can be formed from other suitable structures that define a protrusion of a complex surface from a layer. For example, the protruding structure 137 can be formed in place while avoiding plastic deformation in the material of the layer. In another embodiment, the protruding structure 137 can include a second capped structure adhered to the surface of the layer by heat sealing or other means. Although not necessarily enumerated herein, as will be understood by those skilled in the art, other suitable structures that define a complex surface protruding from a layer are also contemplated herein.

[0049] According to various embodiments, the protruding structure 137 can protrude from one layer to define a one-way direction of chamber protrusion or protrude from both layers to define protrusion from both surfaces of the web 100. In one example, the protruding structure 137 protrudes from one formed layer (e.g., 105) but not from the base layer (e.g., 107). In such an example, the base layer (e.g., 107) forms part of a bounded cavity, defined by a natural shape according to hydraulic pressure, while the protruding structure of the formed layer (e.g., 105) takes the shape to which the protruding structure 137 is applied. Thus, the base layer (e.g., 107) does not necessarily protrude at the position of the cavity without internal fluid pressure. Even when internal pressure exists, the base layer (e.g., 107) protrudes minimally or significantly less than the protrusion of the chamber 120 in the same region of the web 100. In another embodiment, the protruding structure is defined in both layers but in non-opposing positions. In other words, at the position where the protruding structure 137 is disposed in one layer, the protruding structure 137 is not disposed at the position directly opposite the other layer. In another embodiment, various protruding structures 137 are defined independently of both layers at the same or similar positions such that the chamber protrudes in both directions at the overlapping positions of the layers. Although shown as circular in one example, it should be understood that the protruding structure 137 can include various suitable shapes and dimensions. For example, the protruding structure 137 can be rectangular, triangular, elliptical, oval, etc.

[0050] In contrast to conventional protective packaging that includes a pre-formed inflated enclosure (see, e.g., bubble wrap), here, according to various embodiments, the protruding structure 137 closes the cavity 135 defined thereby in a manner that allows the cavity 135 to be expandable and / or contractible after the manufacture of the web 100. For example, each of the cavities 135 can include an inflation port 123. The channel 125 can be connected to the inflation port 123 or a similar suitable structure for adding fluid to or removing fluid from the cavity 135 after the formation of the cavity 135. In some embodiments, the various cavities 135 are also contractible and expandable after the manufacture of the web 100. This is in contrast to conventional protective packages, such as bubble wrap, where fluid is trapped within the bubbles during manufacture and there is no way to contract the bubbles without destroying the bubbles after manufacture of the material, and the bubbles are not refillable. According to various aspects of the present disclosure, the cavity 135 can be expanded after the manufacture of the web 100 and after the cavity 135 of the web 100 has contracted. This can be done by injecting air into the inflation port 123 of the cavity 135.

[0051] According to various embodiments, the plurality of cavities 135 are expandable and contractable and cooperate to form chamber 120. For example, sub-chamber 139 may have an inflation port 123 interconnected with another sub-chamber 139 by channel 125. A group of interconnected sub-chambers 139 cooperate to form a chamber 120 having a common inflation channel 125 suitable for distributing liquid to each of the sub-chambers 139 via their respective ports 123. As shown in the example of FIGS. 1A-1B, the common inflation channel 125 can be a channel that extends continuously (i.e., daisy-chain connected) between columns of chambers 120. In another embodiment, the common inflation channel may be a manifold that extends parallel to each of the chambers 120 (e.g., as shown in the example of FIG. 4B, isolated chambers are supplied in parallel from adjacent chambers). According to various embodiments, channel 125 can extend from expandable region 114. In some embodiments, web 100 includes a plurality of chamber channels 125, each chamber channel 125 being directed to a separate chamber 120. For example, as shown in FIGS. 1A-1B, a plurality of channels 125 extend from expandable region 114. In this embodiment, each channel extends laterally across the material from the longitudinally expandable region 114. Further, different groups of chambers are provided along the longitudinal length of web 100.

[0052] Chamber 120 has a boundary sufficient to hold fluid after being sealed. In some embodiments, chamber 120 may be expandable after being formed. In some embodiments, chamber 120 may be contractable after being formed. In some embodiments, chamber 120 can allow fluid to pass back and forth between sub-chambers even after the final seal is applied to the chamber, preventing additional fluid from being added to the chamber. In some embodiments, chamber 120 is also contractable after being formed and before being sealed.

[0053] As shown by way of example, the web 100 can include a row of chambers 120 formed from a plurality of sub-chambers 139, each chamber being connected to an inflatable region 114. In this way, fluid injected into the inflatable region 114 can pass through channels 125 and enter inflation ports 123 of each sub-chamber 139 that fills the sub-chambers 139 and the chambers 120.

[0054] According to various embodiments, the web 100 can have a relatively small number of large chambers per cross-section (i.e., between the weakening lines discussed herein). For example, each section may have one large chamber. In another example, each section may have two to five chambers. In another example, each section may have five to twenty chambers. In other embodiments, the web 100 can have a relatively large number of protruding structures that may or may not form chambers. The large number of protruding structures are called caps. The caps can be the plastically deformed protruding structures 137 as described above. For example, twenty or more plastically deformed protruding structures per section can be called caps.

[0055] In some embodiments, the cavities 135 may be individually inflatable. For example, each cavity 135 can include an individual inflation port to the outside of the web 100. Such inflation ports can include one-way valves, sealable ports, mechanically closable ports, and the like.

[0056] According to various embodiments, when the web 100 is inflated and ready to be used as protective packaging, one or more of the inflation opening 123, the channel 125, or the inflatable region 114 can be sealed to cause at least partial separation within the chamber 120 and / or the sub-chamber 135. When the final seal is applied, embodiments without valves are no longer sealable or shrinkable. Until this point, liquid pushed into one or more of the inflatable region 114, the inflation opening 123, the channel 125, the sub-chamber 135, or the chamber 120 can be pushed back and pushed in again. This can expand the material and then contract it to a more condensed state, facilitating handling and transportation. After being handled and when ready to be used as protective packaging, the web 100 is inflated and the final seal is applied.

[0057] According to various embodiments, the inflation channel 125 can be a protrusion extending within the formed layer 105. These extended inflation channels 125 can be made in the same manner as the above-described protrusion structures 137. For example, these channels can have structures that include plastic deformation within the formed layer 105. In other embodiments, the channel 125 may be formed by an unsealed region between the formed layer 105 and the base layer 107. Then, fluid can pass between the unsealed layers 105 and 107. Then, the seal can join the sides of the channel to direct the fluid from one cavity to the next. In various embodiments, the channel is significantly smaller than the chamber 120 and / or the protrusion structure 137.

[0058] In some embodiments, the fluid retention cavity can be an isolated cavity 121 that is filled with fluid during formation, such as the plurality of isolated cavities 121 shown in FIGS. 5A and 5B. The isolated cavity 121 does not have an inflation port and can therefore release liquid only upon rupture. Similar to the expandable cavity 135 described above, the isolated cavity is formed from a protruding structure 137 similar to the one described above. However, by way of distinction, the isolated cavities 121 do not have an inflation port or a connected channel and therefore cannot expand or contract unless ruptured, and are filled when they are formed. An example of this structure is shown in FIGS. 5A-5C. Here, the layers 105 and 107 are sealed to each other along the entire circumference of the cavity 121 without the presence of an inflation port or a channel.

[0059] In some embodiments, the isolated cavity can include channel 09 within the chamber and can have longitudinal seals along edges 113 and 115, along with a final seal along the expandable region after expansion. Each of these outer seals surrounds the region around the protruding structure 137. Seal 155 holds the third layer 109 to the outer surface of the protruding structure 137. In some embodiments, seal 155 holds the third layer 109 against the crests 140 of the plurality of protruding structures 137. According to some embodiments, the protruding structure 137 has a flattened crest 140 onto which the third layer 109 is sealed. By having the third layer 109 sealed to the crests 140 of the protruding structure 137 via seal 155, the third layer 109 is distributed across the plurality of protruding structures, enabling it to have a relatively flat structure. The rigidity of the third layer 109 may be affected by variations in the protruding structure 137 along the formed layer 105. The chain of protruding structures 137 may be parallel, offset, and / or in any other suitable configuration. According to various embodiments, the expandable web 154 has a minimum height of at least about 1 mm, 5 mm, or 10 mm and a maximum height of 10 mm, 15 mm, or 30 mm when expanded. However, it should be noted that the expanded expandable web may incorporate other suitable minimum and / or maximum heights. According to various embodiments, the expandable web 154 has a minimum diameter of at least about 1 mm, 5 mm, or 10 mm and a maximum diameter of 10 mm, 15 mm, or 30 mm when expanded. However, it should be noted that the expanded expandable web may incorporate other suitable minimum and / or maximum diameters.

[0060] In the embodiments described below, the volume between layer 105 and layer 109 and within the seal is the second cavity 133. Here, the second cavity 133 containing fluid is shown. In some examples, the fluid may be open to the atmosphere (e.g., see FIGS. 2A - 3B) or the fluid may be sealed. For example, the fluid may be captured here when layer 109 is sealed to layer 105. In some embodiments, this cavity 133 is passively expandable (e.g., FIGS. 2A - 3B). In some embodiments, this cavity 133 is actively expandable via expansion channel 146 (e.g., FIGS. 5A - 6). In some embodiments, cavity 133 is expandable together with and / or sealable together with cavity 135 defined by protruding structure 137 (as shown in FIG. 5B). In some embodiments, the second cavity 133 can form a chamber that is expandable separately from and / or sealable separately from cavity 135 defined by protruding structure 137 (as shown in FIG. 5C).

[0061] In various embodiments, the web 100 includes one or more separation regions 126. The separation regions 126 facilitate the separation of two adjacent web portions, such as a divided group of chambers 120. The separation regions 126 can be disposed along the inflatable chambers 135, between the inflatable chambers 135, and / or along other suitable locations of the web 100. The separation regions 126 can be separated, for example, by manually tearing the web 100 or using tools or machinery. The separation regions 126 can facilitate either or both partial or complete separation of adjacent inflatable chambers 120. As shown in FIG. 1B, the separation regions 126 are disposed between the chambers 120. In this way, the chambers 120 can be easily separated from each other. In the embodiment of FIG. 1B, thin lateral seals 118 are disposed adjacent to the separation regions 126 on both sides. Although shown adjacent to the seals 118, the separation regions 126 can also extend through the seals 118 or through layers 105, 107, 109 that are not attached (as included in certain embodiments), for example, through various inflatable cavities and the layers that define them. In various embodiments, the separation regions 126 can include frangible lines that can be used to separate the regions.

[0062] As an example, FIG. 1A shows an exploded view of an inflatable web having inflatable sub-chambers, and FIG. 1B shows an inflatable web 100 having inflatable sub-chambers 139 that form a plurality of lateral chambers 120 repeated longitudinally along the length of the inflatable web 100. Each of the sub-chambers 139 within each chamber 120 is connected by a channel 125. The channels 125 are also connected to an inflatable region 114 for inflation or contraction of the chambers 120. In some examples, the web shown in FIG. 1B can be made of only layers 105 and 107 or the web shown in FIG. 1B can be made of more layers such as layers 105, 107, and 109. These are merely examples, and it should be understood that any suitable number of layers can be used to form the web 100. The connected sub-chambers form the chambers 120.

[0063] Figures 1C - 1D are cross-sectional views of the inflatable web 100 based on another specific embodiment of FIG. 1B. Here, the web 100 includes layers 105, 107, and 109. Again, these are merely examples, and it should be understood that any suitable number of layers can be used to form the web 100. As shown in the cross-section of FIG. 1C cut along the cutting line IA - IA shown in FIG. 1B, and as shown in FIG. 1D cut along the cutting line IB - IB shown in FIG. 1B, the protruding structure 137 is formed in the layer 105 and sealed to the base layer 107 that forms the sub-chamber 139. The connected sub-chambers form the chamber 120. The third layer 109 can be sealed to the layer 105 formed at the apex of the protruding structure 137. The cavity defined therebetween is the second cavity 133. One inflatable region 114 is formed between the layers 105 and 107. Fluid can be injected into the chamber 120 through the inflatable region 114. In some embodiments, the third layer 109 extends across each of the protruding structures 137. Alternatively, the third layer 109 can extend across a part of the protruding structure 137.

[0064] Figures 2A - 2B show another example of the passively inflated cavity 133. In this embodiment, the third layer 109 includes openings 179 near its edges 101, 113. The openings 179 allow air to pass through the layer 109 and reach the cavity 133 between the base layer 109 and the forming layer 105. Thus, when the chamber 120 expands, the cavity 133 is filled with fluid (e.g., air). This restricts the layer 109 from adhering to the layer 105 via a vacuum.

[0065] Figures 3A - 3B show another example of the passively inflated cavity 133. In this embodiment, the inflatable web 100 includes an inflatable sub - chamber and a perforated third layer 109. The perforations 177 penetrate the third layer 109 but not the other layers. The perforations 177 allow air to pass through layer 109 and reach the cavity 133 between layer 109 and the play 105 formed therewith. Thus, when the chamber 120 expands, the cavity 133 is filled with a fluid (e.g., air). This restricts the layer 109 from adhering to the layer 105 via a vacuum therebetween.

[0066] In other examples, Figures 4A - 4D show other examples of the web 100. Although not all references are shown, each of these webs can be formed according to the various structures described above, as would be understood by one of ordinary skill in the art and as applicable to specific examples. For example, Figure 4A includes an inflatable web 100 having a sub - chamber 139 that forms the chamber 120. However, in this embodiment, the chamber 120 is disposed at an angle 131 with respect to the inflatable region 114. This angle 131 can improve the contraction of the chamber after it is first formed. This will be described in more detail below. Figure 4A also shows the end of the chamber 129. The chamber 120, like other chambers 120, terminates before crossing the web 100. In the case of having a chamber 129 with an early termination, a gap is formed, allowing a frangible line to be applied to form a separation region 126. Figure 4B illustrates an inflatable web 100 having an end of the chamber 129, similar to Figure 3A. However, Figure 4B also includes an isolated chamber 144. Here, the channel 138 branches from the channel 125b or the sub - chamber 139a and can thereby supply the chamber 144. Next, the channel 138 supplies the isolated chamber 144 parallel to the main channel 125b that supplies the next adjacent chamber 145.

[0067] FIG. 4C shows an expandable web 100 having alternating orientations of expandable sub-chambers 139. Here, each sub-chamber 139 is connected to the next adjacent sub-chamber 139 via a channel 125. Each of the different channels departs from the sub-chamber at an opposite angle. This leaves an alternating pattern of sub-chambers 139, forming a zigzag chamber design. By doing this, more sub-chambers 139 can be packed into a single web 100.

[0068] In FIG. 4D, the chamber 120 has a linear lateral orientation with channels 125 connected to a central expandable region 114a. One set of channels 138 exits the expandable region in one direction and another set of channels 125b exits the expandable region in the opposite direction. This allows the chamber 120 to extend in both directions from the expandable region. In such an embodiment, a final seal for sealing the chamber 120 is applied on both sides of the expandable region 114a.

[0069] In FIG. 5A, the expandable web 100 has fluid that penetrates the web 100 along one or more directions 136. Here, the expandable web 100 includes an isolated cavity 121. The cavity 121 is surrounded by a second cavity 133. The expandable region 119 directs liquid to the second cavity 133. The final seal along the expandable region 119 seals the liquid within the second cavity 133. FIG. 5A also shows a segment seal 153. The segment seal 153 seals the second cavity 133 from the frangible line 126. Thus, a segment of the web 100 can be torn along the frangible line 126 without rupturing the second cavity 33. FIG. 5B is a cross-section of the expandable web of FIG. 5A taken along the section line VA-VA. FIG. 5B shows the isolated cavity 121 formed by the protruding structure 137 within the formed layer 105. The seal formed between the layer 105 and the base layer 107 isolates the cavity 121. The third layer 109 is then sealed to the layer 105 with a seal 155 to form the second cavity 133. FIG. 5C includes a variation of FIG. 5B where the cavities are connected to each other via channels 166 within the chamber. Here, the cavities are still filled with fluid at the time of formation of the expandable web, but the fluid can move between the connected cavities, otherwise the cavities cannot contract without being destroyed.

[0070] In FIG. 6, the cavity 133 is sealed on three sides, forming an expandable cavity from the expandable region 114. The expandable region 114 includes an opening 181 into the cavity 133. When the longitudinal seal 303 is applied, the opening 181 is separated from the cavity 133, thereby sealing the cavity 133 and capturing liquid therein. In this way, both the chamber 120 and the cavity 133 expand actively with fluid.

[0071] The expandable structure of the expandable web is disposed between and adhered to outer layers and holds the outer layers spaced apart from each other along a region of the expandable web. Thus, this expandable structure acts as an expanded inner structure between the outer layers. The forces applied between the outer layers and the inner structure provide rigidity and stiffness to the structure and cause the expandable web to act as a framed structure, similar to an I-beam, truss, or other similar framed structure.

[0072] As used herein, the verb "expanded" refers to the active injection of fluid. The term "expandable" as an adjective can represent a fluid "injected" into a chamber or cavity, or alternatively, the term can represent a chamber or cavity occupied by a fluid, whether the fluid has been injected or confined within the chamber or cavity by a manufacturing process or the like.

[0073] The protective packaging material described above can be used with a backing sheet to form an envelope or postal article suitable for protecting the contents therein. The backing sheet can be laminated on the outside. The backing sheet can comprise at least one of cardboard, a polymer sheet, kraft paper, or a fiberboard (e.g., cardboard). Thereafter, the postal article or envelope is formed as a padded envelope, also known as a cushioned postal article. It can also be an envelope incorporating a protective pad for protecting the item during transportation. Here, the web 100 can be used as the pad.

[0074] According to various embodiments, protective packaging manufacturing systems 200, 300 are provided that are suitable for forming an inflatable web 100 and / or inflating the web 100 into a protective packaging material. According to various embodiments, as shown in FIGS. 7A - 8, the web forming apparatus 200 can include one or more elements for forming an inflatable region in at least one of the layers. The web forming apparatus 200 can include film supply units 210, 211 and film supply units 220, 221. The film supply units 220, 221 distribute the formed layer 105. The film supply units 220, 221 direct the formed layer 105 to the expansion volume forming apparatus 240. The expansion volume forming apparatus 240 forms a protruding structure 137 on the formed layer 105. The web forming apparatus 200 also includes an attachment element 250. The attachment element 250 faces the expansion volume forming apparatus 240 and receives the base layer 107 from the film supply units 210, 211. The attachment element 250 presses the base layer 107 against the formed layer 105, while the volume forming apparatus 240 presses the formed layer 105 against the base layer 107. The attachment element 250 serves to seal the layers 105 and 107 together. When the formed layer 105 is sealed to the base layer 107, some liquid is trapped within the protruding structure 137 and expands at least partially. In embodiments where the web 100 includes isolated cavities, the protruding structures 137 contain all of the fluid they receive within them.

[0075] The sealed layer forms web 100. In some embodiments, the formation of web 100 can end at this point. In other embodiments, a third film layer 109 can be added. In such embodiments, web 100 is directed towards the second attachment device 260. Additional film supply units 230, 231 direct film layer 109 towards the second attachment device 260. The second attachment device 260 has opposing elements 261, 262 that can press film layer 109 against the formed layer 105 and attach two together to the peaks of the protruding structures 137 on the formed layer 105. Web 100 is directed towards the shrinkage element 270. The shrinkage element 270 includes opposing elements that compress web 100 and extrude at least a portion of the fluid contained therein to form compressed web 100c. This compresses web 100 and facilitates handling or transportation. A second set of processing elements 280 can also be included. These processing elements can remove additional fluid from web 100, guide web 100 onto a roll, or perform any other beneficial processing steps. Compressed web 100c can be directed towards a storage mechanism 290 that can prepare a web for transportation or prepare it for inflation by inflation system 300.

[0076] According to various embodiments, various film supply units 210, 211; 220, 221; and 230, 231 provide film to a system for forming web 100. In some embodiments, the film supply unit is a roll (e.g., 210, 220, 230) or a fan-fold film supply unit. In some embodiments, the film can be formed in a web forming system via a film extruder (e.g., 211, 221, 231). The film extruder can manufacture the film and direct the newly produced film towards a shaping device. Film supply unit 210 can further include a guiding path that includes rollers arranged to properly direct the film.

[0077] According to various embodiments, the extended volume forming device 240 forms the above-described protruding structure and / or sub-chamber. In one example, the forming device 240 includes an array of chambers that form recesses 242. The chambers that form the recesses 242 can be included as part of a chamber forming die. In some examples, the chamber forming die is part of a rotating cylinder. In various embodiments, the chamber forming device includes at least one of a thermoforming, vacuum forming, or pressure forming mechanism. In some embodiments, the forming device 240 is heated to improve the formation of the protruding structure 137. In this way, the formed layer 105 is heated by the forming device 240 and then evacuated or otherwise drawn into the chambers that form the recesses 242, causing plastic deformation of the layer in each of these recesses to form the protruding structure 137. In other embodiments, the forming device 240 is heated to seal the formed layer 105 to the base layer 107. For example, each of the chamber forming recesses 242 includes therein a vacuum port 241 suitable for applying a vacuum to the formed layer 105 disposed directly against the chamber forming device 240. The film layer is drawn in and plastically deformed to take the shape of the chamber forming recess. In this way, the forming device 240 can plastically deform the surface of the formed layer 105 to form a protruding structure 137 that can define a cavity or sub-chamber as described above. The chamber forming device 240 can also include channel recesses 243. The channel recesses can form channels 125 that extend into the formed layer 105. The channels are formed by plastically deforming a film layer positioned directly against the chamber forming device and plastically stretching the material to create a plastically deformed channel. Additionally or alternatively, the channels 125 can be formed by opening a channel region. The unsealed region can include a chamber that forms a recess and a flow path that extends between at least some of the chambers that form the recesses.

[0078] In various embodiments, the chamber forming device 240 can also include additional recesses for forming additional features in the formed layer 105. For example, the chamber forming device 240 can include channel recesses 247. The channel recesses 247 can be formed on the surface of the chamber forming device 240. The chamber forming device 240 can draw the layer 105 into the channel recesses 247 (e.g., via a vacuum port) and plastically deform the elongated channel 132. Additionally or alternatively, the chamber forming device 240 can include expandable region recesses 245. The chamber forming device 240 can draw the layer 105 into the expandable region recesses 245 in the 249 direction (e.g., via a vacuum port). In some embodiments, the expandable region recesses 245 and / or the channel recesses 247 can actively pull and deform these regions of the layer 105. In some embodiments, the expandable region recesses 245 and / or the channel recesses 247 may simply lack sufficient pressure to press the layer 105 against the layer 107 along these regions to form a sufficient seal. Without a seal, liquid can pass through these regions. In this way, features (e.g., expandable regions and / or channels) can be formed without plastic deformation.

[0079] In various embodiments, the forming device 240 can include a pinch region that includes a surface having a sufficiently minimal gap with the attachment element 250. For example, the forming device 240 can include pinch surfaces 244, 246, and / or 248. The pinch surface 244, when heated (or the web is sufficiently hot) and pressed against the attachment element 250, can form the seal 118. The pinch surface 246, when heated (or the web is sufficiently hot) and pressed against the attachment element 250, can form the seal 113. The pinch surface 248, when heated (or the web is sufficiently hot) and pressed against the attachment element 250, can form the seal 115. According to various embodiments, the chamber remains unsealed, partially sealed, and / or partially closed during inflation. According to some embodiments, the chamber need not remain closed during inflation.

[0080] According to various embodiments, the attachment element 250 serves to attach the base layer 107 to the formed layer 105. In various embodiments, the attachment element 250 is an opposing surface disposed near or opposite the forming device 240. The attachment element 250 can apply pressure to the forming device 240 when the film passes between them. Additionally or alternatively, the attachment element 250 can apply heat to cause a seal. Additionally or alternatively, the attachment element 250 can apply an adhesive to cause sealing. In various embodiments, the attachment element 250 is a cylinder that rolls against or near the cylindrical die of the forming device 240 (forming a nipping device). Thereby, the layer therebetween is compressed and sealed. This process can form seals 118, 113, 115, etc., and can also form the protruding structure 137.

[0081] According to various embodiments, attachment element 260 serves to attach the film layer 109 to the formed layer 105 by forming a seal 155, as discussed according to the above-described embodiments. In various embodiments, attachment element 260 includes opposing surfaces 261 and 262 that are in proximity to each other or arranged opposite to each other. In embodiments where cavity 121 is isolated and fluid cannot escape, the opposing surfaces can be sufficiently spaced so as not to break the cavity and to sufficiently seal the third layer 109 to the formed layer 105. Attachment element 260 can apply pressure between surfaces 261 and 262 as the film passes between them. Additionally or alternatively, attachment element 260 can apply heat to cause a seal. Additionally or alternatively, attachment element 260 can apply an adhesive to cause a seal. In various embodiments, attachment element 260 includes two cylinders that roll in opposite directions or near each other (forming a nip device) and form seal surfaces 261 and 262. In various embodiments, attachment element 260 includes a heating element 263 that directs heat to the layers to seal them together. In some embodiments, attachment element 260 is a heating drum that heats the layers when they come into contact.

[0082] According to various embodiments, the compression / shrinkage element 270 compresses the web 100 and removes some or all of the fluid contained therein. As described above, the liquid is or can be trapped within the web 100 during the formation of the protruding structure 137. To facilitate handling, in order to compress the web 100, the web can be compressed to extrude the liquid from the expandable regions 119 and 114. When the isolated cavity 121 is formed, the shrinking process can focus on removing the fluid from the second cavity between the layers 105 and 109 so as not to break the isolated cavity. In some embodiments, the expandable regions 114 and / or 119 can be open regions, i.e., this means that there is no end seal or discontinuous end seal 113 that allows the liquid to be discharged along the length of the web 100. In some embodiments, the seal 113 can be added later. For example, the second element 280 can be a seal element that applies a longitudinal seal such as 113. In one embodiment, as shown in FIG. 6, a pair of compression rollers 171B, 172a are arranged at an angle with respect to the flow of the web 100 passing through the system. This angle allows the rollers 171B, 172a to compress the chambers and cavities of the film on the opposite side of the expandable region 114 as the film progresses and move towards the expandable region 114. This helps to limit the trapping of air by the rollers 171B and 172a. In other embodiments, the compression elements 171C, 172b can be perpendicular to the flow of the material, as shown in FIG. 8. FIGS. 7A-8 can be distinguished by the angle of the compression elements with respect to the movement of the web through the system. In some embodiments, the angled compression elements (see FIG. 7A) may be suitable for removing fluid from a web having a chamber perpendicular to the flow of material through the system 200. This angle to the chamber can limit the trapping of fluid. In other examples, the vertical compression elements 171C, 172b (see FIG. 8) remove fluid from a web having an angled chamber in relation to the flow of material through the system 200 (see FIGS. 4A or 4B).According to various embodiments, the inflatable web supply 290 receives an inflatable web after the first and second opposing shrink elements have shrunk the web. Web storage stores the web in a substantially un-inflated state and enables the web to be transported in a high-density configuration. After transportation, the web can be reinflated for use as protective packaging.

[0083] According to some embodiments, the heat-resistant material 505 disposed along one or more of the formed layer 105, the base layer 107, and / or the third layer 109 is a heat-resistant material configured to prevent a heat seal from being formed between the two layers at a location where the heat-resistant material 505 is processed or disposed between the two layers. This allows channels (e.g., channel 125), chambers (e.g., chamber 135), inlets, outlets, and other non-sealed configurations to remain unsealed after heat is applied to two or more layers 105, 107, 109. The heat-resistant material 505 can be applied to one or more layers via suitable means such as printing, spraying, diffusion, or other suitable means. The heat-resistant material 505 can be, for example, glue, ink, powder, adhesive, and / or other suitable forms configured to be applied to one or more of the layers 105, 107, 109.

[0084] As shown in FIG. 9, the heat-resistant material 505 is applied to the layer 107 in the pattern 510, where the layer 107 does not heat-seal to the layer 105 everywhere the heat-resistant material is disposed on the layer 107. On all untreated areas 515 of the layer 107 not treated with the heat-resistant material 505, the layer 107 can heat-seal to another layer (105 or 109) at locations not treated with the heat-resistant material 505. As shown in FIG. 9, the heat-resistant material 505 can be applied to the third layer 109 in a pattern 520 configured such that the peak 140 of the protruding structure 137 can seal to the third layer 109 at the untreated area 515 of the third layer 109. The layer 109 can be applied to the layer 105 in the direction 201. The layer 107 can be applied to the layer 105 in the direction 202.

[0085] By applying a heat-resistant material 505 between the formed layer 105 and the second layer 109, the first layer 105 and the second layer 107 can be adhered together with the chamber 135 and the channel 125, and as shown in FIG. 10, it can be expanded and sealed before applying the third layer 109.

[0086] According to various embodiments, the flexible expandable web 154 includes a plurality of walls as shown in FIGS. 11A-11B. The plurality of walls may be by a single layer 105 (as shown in FIGS. 11A-11B) or by a plurality of layers. As shown in FIGS. 11A-11B, the base layer 107 is adhered to the peaks 140 of the first side portion 151 of the flexible expandable web 154, and the third layer 109 is adhered to the peaks 140 of the second side portion 152 of the flexible expandable web 154. When the cavity 135 expands with fluid, the base layer 107 conforms to a shape defined by the tangents from the plurality of peaks 40 of the first side portion 151 of the flexible expandable web 154, and the third layer 109 conforms to a shape defined by the tangents from the plurality of peaks 140 of the second side portion 152 of the flexible expandable web 154. The plurality of peaks may each or both conform to a two-dimensional (2D) pattern. According to various embodiments, the outer layers 107 and / or 109 extend along a virtual first tangent plane, bridging the valleys of the undulating surface of the flexible expandable web 154, such that when the chamber expands, the attached outer layers and the expandable web cooperate to form a frame structure having a significantly higher bending stiffness compared to the bending stiffness resulting from an expandable web structure without the attached outer layers.

[0087] Next, referring to FIGS. 12A-12B, an inflation and sealing device 300 (FIG. 12A) is shown having an inflation and sealing mechanism 355 (FIG. 12B) for converting an inflatable web 100 into a series of inflatable walls or cushions 305. The uninflated inflatable web 100 can serve as a large source of uninflated material 310. For example, as shown in FIG. A, the uninflated inflatable web 100 can be provided as a roll 315 of supply material that can be wound around an internal support tube 325. In some embodiments, the supply material is wound around a roll 315 having a hollow center. The support tube 325 or hollow center of the roll of material 134 is supported by a supply support element 330 of the inflation and sealing device 300, in this case, supported on the roll axis. The roll axis 330 houses the center of the roll of web material 100 or the tube 325. In other embodiments, different structures such as trays, fixed spindles, multiple rollers may be utilized to support the roll of material, or different configurations of supply material (e.g., folded supply material) may be used. In some embodiments, the web 100 is fed from a folded configuration such as a fanfold configuration 320 (as shown in FIG. 10).

[0088] The inflation and sealing device 300 includes handling elements, each of which includes a web support portion. The web support portion supports and directs the expandable web 100 of material longitudinally 335 along a path. The handling element can include a supply support element 330 that supports the supply material 310 of the web 100 in an unexpanded state. The inflation and sealing mechanism 355 is operable to expand the web 100 with fluid and seal the layers 105, 107 together to seal the fluid therein by directing fluid between the overlapping layers 105, 107 of the web 100. Two of the web support portions (e.g., roll shaft 330 and guide member 340) are arranged relative to each other and to a support structure 345 such that when the supply material 310 passes from the first web support portion to the second web support portion, it receives different amounts of tension along the transverse direction. The relative positions of the two web support portions create a difference in tension between two portions of the web 100 that are transversely arranged relative to each other at substantially the same longitudinal position along the path. In a further embodiment of the invention, the tension difference can be achieved by providing one or more inflation elements on the guide member 340, as further described below. In some examples, the resulting shape of the guide member 340 defines the longitudinal movement distance between the first and second adjacent web branch portions at one transverse end of the web to be slightly shorter compared to the longitudinal movement distance between the first and second adjacent web support portions at another (e.g., opposite) transverse position of the web, as further described.

[0089] The web material 100 is inflated by a drive device 160 and pulled via a sealing device 300. In some embodiments, an intermediate member such as a guide member 340 (which can include, for example, a fixed bar or roller) can be disposed between the supply material 310 and the drive part 350. For example, any guide member 340 can extend substantially vertically from a support structure 345. The guide member 340 can be arranged to guide the web 100 away from the roll 315 of the material 100 and along a material path 335 where the material is processed, which is also called a longitudinal path. The guide member 340 is disposed between a material support 330 that supports the supply material and the configuration of the inflation and sealing mechanism 355 of the inflation and sealing device 300. The guide member 340 can be arranged to feed the web material 100 from the supply section towards the inflation and sealing mechanism 355 such that the web material 100 follows a curved longitudinal path. The guide member 340 can include one or more surfaces that define a web support surface (for example, a surface that extends along the side surface of the guide member 340 where the web 100 bends around when crossing the path 335). In some examples, as further described below, the guide member 340 can include one or more inflation elements. The one or more inflation elements can provide at least a portion of the web support surface of the guide member 340 and can configure the guide member 340 to provide variable tension to the web material 100 at different lateral positions of the web material 100.

[0090] The guide member 340 or a part thereof can be movably connected to the inflation and sealing device 300 such that when the web material 100 is being pulled out from the roll 315 by the drive unit 350, the guide member 340 or its movable part can move (e.g., rotate, translate, vibrate, etc.) relative to the support structure 345. In some examples, the guide member 340 includes a guide roller, which includes a shaft or rod portion and a rotatable or roller portion coaxially coupled to the rod portion such that the roller portion rotates about a common axis of the rod and the roller portion. The roller portion provides a web support surface for supporting the web 100, in which case the roller portion moves with the web 100 when the web 100 is pulled out from the roll 315. The moving web support surface can reduce or eliminate the sliding friction between the guide member 340 and the web 100. However, in other embodiments, a guide member 340 having a fixed web support surface is also contemplated. For example, the guide member can include a rod similar to a shaft that does not have a rotatable part. To reduce sliding friction, a low-friction material such as polytetrafluoroethylene (PTFE) can be provided on at least a part of the web support surface of the non-rotating rod (e.g., in the form of a coating or a strip of adhered material). In still other embodiments, the non-rotating part or the rod and the rotatable part (e.g., roller) of the guide member need not be coextensive. For example, the only rotating part of the guide member 340 can be an extension member element. The web support surface of the guide member 340 that does not rotate when the web 100 moves over it can be provided by coating or in other ways using a friction-reducing material. In some embodiments, the guide member 340 can be additionally or alternatively coupled to the inflation and sealing device 300 such that it moves in a direction perpendicular to the longitudinal path 335 along which the supply material moves.

[0091] In an embodiment, the guide member 340 according to the present invention includes one or more inflatable elements. In some embodiments, the inflatable elements provide part or all of the web support surface of the guide member 340. Thus, according to the principles of the present invention, the guide member 340 can be configured to control the web material 100, for example, to prevent or reduce sagging of the web material 100 between the roll 315 and the inflation nozzle 375 of the inflation and sealing mechanism 355 of the inflation and sealing device 300.

[0092] In various embodiments, the stock material (e.g., web material 100) can proceed downstream from a supply of material such as roll 315 without engaging the guide roll 340, but instead can proceed directly into the inflation and sealing mechanism 355. As used herein, the terms upstream and downstream are used with respect to the direction of movement of the web material 100. In addition to, or as an alternative to, the use of brakes, guide rollers, or web feed mechanisms, other suitable structures can be utilized to guide the web material 100 toward a sealing region 365 of the sealing mechanism 355 that can form part of the sealing mechanism 355. The sealing region 365 can be a pinch region where the layers 105, 107 of the web material 100 are sandwiched or compressed and heated simultaneously so as to fuse with each other. An inflation fluid can also be supplied to the sealing region 365. As shown, the web material 100 can sag, bunch up, drift along the guide roller 340, become misaligned from alignment with the sealing region 365, alternate between tension and sag, or otherwise be subject to other variations in delivery, so the inflation and sealing mechanism 355 may need appropriate adjustment capabilities to compensate for these variations.

[0093] The web material 100 is inflated by the drive unit 350 and advanced through the sealing mechanism 355. The inflation and sealing mechanism 355 can incorporate the drive unit 350, or the two systems can operate independently. The drive unit 350 includes one or more devices operable to move the flexible structure 100 via the inflation and sealing device 300. In the illustrated embodiment, the drive unit 350 includes a backing element such as a backing wheel 360 driven by a motor via a belt. In other embodiments, the drive unit 350 can include different rollers, wheels, or drums, or two or more of them. In other embodiments, the backing element 360 may be stationary. In some embodiments, the drive unit 350 can include a belt drive, and the belt is in contact with a portion of the web 100. In some embodiments, multiple belts can be used to move the web material 100 through the inflation and sealing device 300. In other embodiments, the belt moves the web material 100 along the material path, and one or more rollers are driven and follow by the movement of the web material 100. In other embodiments, a combination of belts, rollers, or drums moves the web material 100 through the material path 335 via the inflation and sealing device 300. In some embodiments, the various belts, drums, or rollers can be driven by a single motor and connected to other belts, pulleys, or gears to transmit rotational motion throughout the connected drive devices. In other embodiments, the belts, drums, or rollers can be driven by individual motors or servos.

[0094] For example, in various embodiments, the drive unit 350 includes one or more motor-driven rollers operable to move the flexible material 100 in a downstream direction along the material path 335. One or more rollers or drums can be connected to the drive motor so that the one or more rollers drive the system. According to various embodiments, the drive unit 350 drives the web material 100 without the belt contacting the flexible structure. In other examples, the system includes a belt that does not contact the web material 100 and instead drives the rollers. In another example, the system has some drive element belts but not others. In another example, the system can weave the belt throughout the rollers and the material may be driven through the system by the belt.

[0095] The inflation and sealing device 300 includes an inflation and sealing mechanism 355. Preferably, the inflation and sealing mechanism 355 is configured to continuously inflate when the web material 100 is released from the roll 315. The roll 315 preferably includes a plurality of inflatable chambers 135 arranged in series, for example in a chain to form a continuous or semi - continuous web. In some embodiments, the web 100 is a single pad having sealed ends. To initiate the manufacture of the cushion 305 inflated from the web material 100, the inflation opening 116 of the web material 100 is inserted into an inflation assembly such as an elongate guide 375 that guides the web material through the inflation and sealing device 300. The width of the inflation channel 114 can be selected to slide closely around the nozzle and over the nozzle 275 to allow fluid to flow into the inflatable chamber 135. In this embodiment, the elongate guide is also the inflation nozzle 375 and travels along the material path 335. The nozzle 375 has an elongate portion that includes one or more of a nozzle base, a flexible portion, and / or a tip. The elongate portion serves to guide the flexible structure 100 to the sealing region 365. At the same time, the nozzle 375 can inflate the flexible structure via one or more fluid outlets 380. In this embodiment, the fluid outlet 380 is an opening in the nozzle 375. The one or more fluid outlets 380 exit from one or more of the inflation channels 114 in the nozzle base, the flexible portion, or the tip. The tip includes a terminal portion that can act as a guide to initiate the guiding of the nozzle 375 into the inflation channel 114. The terminal portion is a hemispherical plug in the illustrated embodiment, but other shapes are contemplated. In the illustrated embodiment, preferably, the web material 100 travels over the inflation nozzle 375 with the inflatable chamber 135 extending laterally with respect to the inflation nozzle 375 and the side outlet 380. The side outlet 380 directs fluid laterally with respect to the nozzle base into the inflatable chamber 135 to inflate the inflatable chamber 135 as the web material 100 travels longitudinally along the material path 335. In other embodiments, the outlet 380 directs fluid in other directions with respect to the nozzle base.The inflation nozzle 375 inserts a fluid such as pressurized air through the nozzle outlet into the non-inflated web material 100 and inflates the material into the inflated cushion 305. The inflation nozzle 375 can include a nozzle inflation channel that fluidly connects a fluid source flowing in from a fluid inlet to the nozzle outlet (e.g., the side outlet 380). In other configurations, it is understood that the fluid may also be other suitable pressurized gas, foamed material, or liquid. Next, the inflated web material 100 is sealed by the sealing mechanism 355 in the sealing region 365 to form a chain of inflated cushions 305. Typically, the nozzle 375 has an outer diameter of about 1 / 4 to 1 / 2 inch. In this embodiment, the outer diameter of the nozzle is about 3 / 16 inch. Alternatively, other suitable nozzle diameters can be selected.

[0096] The inflation and sealing mechanism 355 includes a heat sealer 385 that forms a longitudinal seal 303 within the web material 100 in the sealing region 365, captures fluid between the layers 105, 107, and thus forms the cushion 305. The heat sealer 385 includes opposing compression elements 390, 395 that are in a compressed state relative to each other and compress the overlapping layers 105, 107 together within the sealing region 365. The heat sealer 385 includes a heating element that supplies thermal energy to the sealing region 365. The opposing compression elements 390, 395 and the heating element cooperate to generate sufficient compression and heat within the compressed overlapping layers 105, 107 in the sealing region 365 to heat-seal the overlapping layers 105, 107 together, thereby sealing the inflated expandable chamber 135 and capturing the fluid. Other suitable sealers, such as ultrasonic welders or adhesive sealers, can be used.

[0097] In the illustrated embodiment, the compression element 395 is provided as a rotary seal element 400. The rotary seal element 400 is arranged such that the compression element 395 contacts one side of the web material 100 (e.g., one of the layers 105, 107) and contacts the opposite side of the web material 100 (e.g., the other of the layers 105, 107) within the sealing region 365 facing the compression element 390, forming the longitudinal seal 303 and capturing the inflation gas within the inflatable chamber 135. According to some embodiments, the rotary seal element 400 has a relatively narrow protrusion that forms the compression element 395 around it. In FIG. 12B, for the sake of convenience, the rotary seal element 400 is shown partially retracted from the compression element 390 with respect to the seal position. Certain components of the inflation and sealing device 300 are visible behind the web material 100. The transverse wall extends inwardly from the protrusion towards the axis of rotation of the seal element 400. In this embodiment, the inflation nozzle 375 functions as an air injector by discharging air (or other inflation fluid) along the path 405 through one or more outlets 380 arranged along the nozzle 375. In other embodiments, a separate injector from the nozzle 375 can be used to inject the inflation gas into the inflatable chamber 135. In some embodiments, the seal element 400 includes a non-stick release coating to prevent adhesion of the web material 100 thereto and reduce friction.

[0098] According to some embodiments, the heating element is an electrically powered plug or cartridge heater. The heating element can be heated electrically, for example, by providing an electrical resistance that converts electrical energy into thermal energy. The heating element can be powered by direct current or alternating current, and the alternating current can be single-phase or three-phase power. The heat generated by the heating element can conduct and convect from the heating element to the rotary seal element 400 and the compression element 395.

[0099] The heating element can be of any material or design suitable for sealing adjacent layers 105, 107 together. In various embodiments, the heating element may be a resistance wire or foil. The wire or foil can be formed of nichrome, iron-chromium-aluminum, cupronickel, or other metals suitable for forming and operating a heating element under conditions used to seal together layers of flexible materials, enabling the heating element to melt, fuse, join, bond, or bring together the two layers 105, 107. In some embodiments, the heating element is formed from approximately 80% nickel and 20% chromium that is softly annealed. In other embodiments, the heating element 375 can be a thin-film heating element. The thin-film heating element can be formed of a composite material of barium titanate and lead titanate, or other materials suitable for forming and operating a heating element under conditions where the heating element can obtain sufficient heat to seal layers together.

[0100] In the illustrated embodiment, the sealing element 400 is attached such that its axis is fixed relative to the support structure 345. In other embodiments, the sealing element 400 can be displaceably attached manually or mechanically toward or away from the compression element 390.

[0101] For example, if the operation of the inflation and sealing device 300 is interrupted to prevent combustion of the web material 100, it may be desirable to pull the sealing element 400 away from the web material 100. For example, the position of the sealing element can be adjusted to increase or decrease the pressure between the compression element 395 and the compression element 390. For example, the actuator 405 actuates a cam via a belt. A cam follower rides on the cam, moving the sealing element 400, resulting in the spring being compressed or decompressed to generate a sealing force, more or less, between the compression elements 390, 395. The sealing pressure can be adjusted, for example, to accommodate web materials 100 of different thicknesses, different materials, or different numbers of layers.

[0102] In the illustrated embodiment, the seal element 400 is a free wheel and is rotated, for example, by the movement of the web material 100 against which the seal element 400 is pressed. In other embodiments, instead of the free wheel seal element 400, a motor can be provided to cooperate with other drive mechanisms to rotate the seal element 400.

[0103] In some embodiments, the seal element 400 can be made of a metal such as aluminum, steel, brass, bronze, or other suitable materials. Thus, the seal element 400 can have a significant thermal mass. For example, the seal element 400 can have sufficient thermal mass to maintain a constant temperature to continuously seal layers 105, 107 as they move through the sealing region 365. A temperature sensor such as a thermistor or thermocouple can be provided to sense and control the temperature of the heat sealer 385. The temperature of the heat sealer 385 can be controlled to about 100 - 450 °C, or preferably 260 - 310 °C, or more preferably 280 - 290 °C. According to various embodiments, the heat sealer 385 is heated to about 150 °C to 250 °C. In some embodiments, the heat sealer 385 reaches about 200 °C. The peripheral portion of the heat sealer 385 can reach a lower temperature of about 50 - 100 °C.

[0104] As shown in FIG. 12B, the compression element 390 is disposed on the backing wheel 360. The compression element 390 is an elastic member that extends around the backing wheel 360. The backing wheel 360 is driven by a motor. In other embodiments, the backing wheel 360 may be a free wheel and may be driven by a drive wheel that frictionally engages the compression element 390. The compression element 390 includes a crown portion 410 that assists in holding the web material 100 in a flat state within the sealing region 365 when supplied through the inflation and sealing mechanism 355. The crown portion 410 has a raised rectangular profile that extends circumferentially from the shoulder portion 415 of the compression element 390. In other embodiments, the crown portion 410 can have other profiles such as a convex or concave profile. The crown portion 410 has a radius that is larger than the radius of the shoulder portion 415. In the illustrated embodiment, the compression element 390 includes two shoulder portions 415 and the crown portion 410 is disposed laterally therebetween. In other embodiments, the compression element 390 can have one shoulder portion 415 or can have a flat cross-section such that it does not have a shoulder portion 415 or a crown portion 410.

[0105] The compression element 390 is typically composed of an elastic material, such as a synthetic rubber like natural rubber or silicone rubber. The elastic surface partially conforms to the compression element 395 and, when the compression elements 390 and 395 engage and press against each other, improves the quality of the seal and increases the dwell time of the seal. The compression element 395 is pressed into the crown portion 410 and distorted into a concave profile that matches the convex profile of the compression element 395. Non-limiting examples of the compression element 395 include drums, plates, wheels, boxes, and other surfaces composed of metal or other rigid materials. The backing wheel 360 can have an elastic material applied to one or more of its surfaces so as to function as the compression element 390. For example, the compression element 390 can be formed by vulcanizing a layer of rubber (e.g., 1 / 4 inch thick) onto an aluminum or steel wheel or other backing element. Alternatively, the compression element 390 can be preconfigured as an elastic band and stretched over the backing element. The thickness of the compression element 390 typically ranges from about 1 / 8 to about 1 / 4 inch. The elastic material needs to be selected so that the web material 100 does not stick excessively to the compression element 390. Also, the elastic material needs to be selected so that it does not degrade with heat. Suitable elastic materials often have a Shore A hardness of about 20 to about 95 durometers, typically about 45 to about 75, and more typically about 50 to about 70. For example, a 60 durometer silicone rubber can be used.

[0106] In other embodiments, the compression element 390 can be a non-rotating fixed element. The surface of such a compression element 390 can curve along the material path 335. The apex of the curve can be located, for example, approximately at the center of the backing element 360 where the sealing element 400 contacts the web material 100. The curved surface of the backing element 360 effectively lengthens the path of the web material 100, which helps to compensate for dimensional changes when the web material 100 is processed. In particular, the length of the web material 100 somewhat decreases as the inflatable chamber 135 (due to the expansion of the web material 100 in the thickness direction) expands. However, the edge portion of the web material 100 that is sealed by the heat sealer 385 does not expand, and thus the length of the edge portion does not decrease as the inflatable chamber 135 expands. As a result, the edge portions of the web material 100 tend to gather when the inflatable chamber 135 expands, for example, in an "accordion" fashion. The curved surface of the backing element 360 increases the length of the material path 335, which helps to keep the web material 100 in a flat state when the web material 100 is expanded and fed through the sealing mechanism 355.

[0107] The inflation and sealing apparatus 300 includes a cutting assembly 420 for cutting the web material 100. The cutting assembly 420 includes a cutter 425 arranged to cut open the inflation channel 114 from the nozzle 375. The cutter 425 can include a stationary cutting element or a rotating cutting element. The cutter 425 can typically be sharp, such as by slicing, abrasive, grinding, or another suitable cutting mechanism.

[0108] As shown in FIG. 12B, cutter 425 is a blade having a sharp cutting edge 430 sharp enough to cut web material 100 as it is drawn through cutting edge 430 along material path 335. The cutting assembly 420 of this embodiment is arranged to cut web 100 at a lateral position between the first longitudinal edge 110 and the inlet channel 125 of the inflatable chamber 135, although in other embodiments other positions such as the position around the inflation nozzle 375 can be used. Cutter 425 cuts web material 100 to open the inflation channel 114 of web material 100, allowing the web to disengage from inflation nozzle 375. In various embodiments, the inflation channel 114 of web 100 may be at the center of web 100 or at other positions, and accordingly, the configurations of the expansion mechanism, the sealing mechanism, and the cutting mechanism are changed.

[0109] Cutter 425 cuts web material 100 at a cutting position 435 where cutting edge 430 is adjacent to the outside of nozzle 375. At cutting position 435, cutting edge 430 faces upstream, and as web material 100 moves along path 335 through cutting position 435, web material 100 is cut to allow inflation channel 114 to disengage from nozzle 375. In this embodiment, as shown in FIG. 12B, cutter 425 projects into the interior of nozzle 375 through a cutter receptacle 440 formed within nozzle 375. As shown, cutter receptacle 440 can be provided as a cutter receiving slot.

[0110] According to various embodiments, the inflatable web 100 may be in a wall or cushion structure 305, as shown in FIGS. 12A - 12B, or in a pouch or C - fold bag structure 445 (as shown in FIGS. 13A - 13C), or in other suitable structures.

[0111] As shown in FIGS. 13A - 13C, a series of packaging bags 445 of the fan - fold configuration 320 (FIG. 13A), cross - sections of a plurality of the packaging bags 445 along the cutting lines XIIIA - XIIIA in FIG. 13A (FIG. 13B), and cross - sections of the packaging bag 445 along the cutting lines XIIIB - XIIIB in FIG. 13A (FIG. 13C) are illustrated.

[0112] As shown, each of the packaging bags 445 includes an opening 450 into which one or more products / items can be inserted. The series of packaging bags 445 includes inflation channels 114 configured such that air passes through the packaging bags 445 on one side, flows around the C - folds, reaches the other side, and is capable of inflating both the front and back of each of the packaging bags 445. According to one embodiment, each of the packaging bags 445 within the series of packaging bags 445 includes one or more separation regions 126 configured to allow each packaging bag 445 to be separated from an adjacent packaging bag 445.

[0113] As described above, the web 100 may be configured as various types of packaging materials including bags. According to the embodiment shown in FIG. 14, the bagging machine 600 is configured to receive the web 100 of pre - formed packaging bag structures 445 and may be configured to open the opening 450 of each bag structure to access the internal cavity 460 of each bag structure.

[0114] In the embodiment of FIG. 14, the bagging machine 600 includes a plurality of fingers 605 and / or telescoping protrusions 610 configured to pull open the bag opening 450, enabling one or more products / items / others to be inserted into the internal cavity 46.

[0115] The web 100 is supplied to the bagging machine 200 in a non - expanded high - density configuration. The web 100 can be in a fan - fold supply configuration 320 and / or other suitable configurations such as a roll configuration 315 (as shown in FIG. 12A) at the supply side of the bagging machine 200.

[0116] The bagging machine 600 includes an expansion device 615. According to various embodiments, the expansion device may be an inflation and sealing device 300 as shown in FIGS. 12A-12B, and / or any other suitable system / device for expanding / inflating the web 100. The expansion device 615 is not limited to an inflation device configured to inject fluid to expand and fill the fluid chambers 135, 133, and includes heating elements, heating coils, air compressors, hot air applicators, high-frequency radiation generators, UV light applicators, chemical reaction applicators, pressure mechanisms, or any other suitable expansion device configured to inject fluid to expand and fill the fluid chambers 135, 133. The fluid may be air or any other suitable fluid. In some embodiments, the expandable element of the web 10 includes a one-way valve for holding fluid within the chamber. For example, in some embodiments, the inlets 128 and 146 of FIGS. 1A-6 can be configured to be one-way valves. In other embodiments, the inlets 128 and 146 of FIGS. 1A-6 can be configured to be two-way valves. In some embodiments, an inflatable chamber requires a longitudinal seal to which it is to be applied. In some embodiments, the expansion mechanism 615 is arranged and configured to expand the expandable element before inserting the product into the internal cavity 460. In other embodiments, the expansion mechanism 615 is arranged and configured to inflate the web 100 after inserting the product into the internal cavity 460. In still other embodiments, the expansion mechanism 615 is arranged and configured to inflate the web 100 while inserting the product into the internal cavity 460.

[0117] As shown in FIG. 14, the expansion device 615 is disposed upstream of the bagging mechanism for feeding the web 100 to the bagging mechanism. The bagging mechanism is configured to seal, separate from subsequent bag configurations, and form individual bags.

[0118] In other embodiments, the expansion device 615 is disposed in or downstream of the bagging for expanding the walls of the web 100 at other points during the bag manufacturing process.

[0119] According to some embodiments, the expansion mechanism 615 is configured to inflate the web 100 before opening the bag opening 450 to insert one or more products into the internal cavity 460. In other embodiments, the expansion mechanism 615 is configured to inflate the web 100 simultaneously with or after opening the bag opening 450 to insert one or more products into the internal cavity 460.

[0120] The web 100 includes one or more frangible regions 126 and one or more openings 460 that are applied before the sealing process. In other embodiments, one or more frangible regions 126 and / or one or more openings 450 are applied during or after the sealing process. The frangible region 126 is configured to be broken to separate one packaging container from the next. The opening 450 is configured, arranged, and can be opened by mechanical fingers 605 and / or suction cups 620 to allow access to the internal cavity 46 of the packaging container structure 445. The use of pressurized air helps to open the opening 450 within the packaging container structure 445.

[0121] According to some embodiments, the fingers 605 are configured to sandwich a portion of the packaging container opening 450, open the packaging container at the opening 450, and provide additional securing means for holding the packaging container in place. The bagging machine 600 can include an air blower 625 configured to apply air pressure to the opening 450 to assist in opening the packaging container. The opening 450 can include a pouch seal. The pouch seal can include an adhesive for sealing the opening 450 when a product is inserted. Other forms of sealing the opening 450, such as heat sealing, can be implemented additionally or alternatively. When the opening 450 is closed and sealed, the frangible region 126 can be broken by suitable means, such as, for example, inverting, cutting, melting, or other suitable means of the next packaging container.

[0122] Each packaging container 445 within the web 100 can be separated by using the tensile force applied to each packaging container 445 to tear the fragile region 126 located between each pair of bags in a series of bags, or by using one or more cutting edges configured to form a tear along a seam connecting two packaging containers 445 within a series of packaging containers 44. In some embodiments, each bag in a series of bags is separated using focused heat configured to melt a portion of a seam connecting two packaging containers 445 within a series of packaging containers 445.

[0123] In some embodiments, the bagging machine is configured to convert and seal the web 100 into one or more finished packaging containers. The web 100 can be supplied to the bagging machine in an extended or non-extended configuration and can be in a roll configuration, a fan-fold configuration, or one or more other suitable configurations.

[0124] When supplied to the bagging machine, the web 100 passes through an expansion device, such as an expansion mechanism 615, configured to expand the chambers of the web 100. According to some embodiments, a portion of the web 100 remains unexpanded to facilitate folding of the web 100. In some embodiments, the lines of the web 100 can form natural hinge lines or regions that bend more easily than the expanded regions, leaving the chambers non-inflatable. In some embodiments, the chambers are pressurized during or after expansion to form hinge lines or regions that bend more easily than other regions.

[0125] The expanded web 100 continues to be fed through a folding device configured to fold the web 100 such that the longitudinal edges of the web 100 contact each other. The folding device can include one or more folding bars configured to fold the web 100 into a C-shape. The folding device can further include a crossbar or other suitable device configured to align the web 100 such that the folded web 100 forms an internal cavity. Once folded, a series of holding mechanisms can leave the web 100 unconstrained, allowing one or more products to be placed within the internal cavity 460, for example, in a side-loading configuration. The web 100 can be disposed vertically, for example, while a product is disposed within the internal cavity 460. In other embodiments, the web can be disposed horizontally or at another suitable angle (e.g., with the opening to the internal cavity 460 facing upward).

[0126] Once a product is disposed within the internal cavity 460, the web 100 is fed to a sealing mechanism configured to seal the longitudinal and transverse seals of the web 100. The sealing mechanism can be configured to apply heat, pressure, and / or other suitable means for setting the seal. In some embodiments, the sealing mechanism is configured to pull the web through a bagging machine for sealing. Once sealed, the web 100 is converted into a formed and sealed bag. According to some embodiments, the bagging machine includes a separating mechanism configured to separate the bag from the web 100. In some embodiments, the separating mechanism is configured to pull the completed bag and tear the completed bag from the next bag along a frangible region 126. In some embodiments, the separating mechanism is configured to separate the bag via a blade or thermal cut. In some embodiments, the separating mechanism may incorporate other suitable separating means. According to some embodiments, the separating mechanism is configured to hold the bag in a predetermined position to allow the sealing mechanism to seal the next bag.

[0127] Examples of components that can be used within the inflation and sealing device 300 include, but are not limited to, nozzles, blowers, sealing mechanisms, and drive mechanisms, and various components or related systems thereof can be structured, positioned, and operated as disclosed in any of the various embodiments described in incorporated references such as U.S. Patent Nos. 8,061,110; 8,128,770; U.S. Patent Publication No. 2014 / 0261752; and U.S. Patent Publication No. 2011 / 0172072 (each incorporated herein by reference). Each of the embodiments discussed herein may be incorporated and used with various sealing devices of the incorporated references and / or other inflation and sealing devices. For example, suitable mechanisms described herein and / or in the incorporated references can be used for the inflation and sealing of the flexible structure 100.

[0128] This disclosure should not be limited to the specific examples described in this application, which are intended as examples of various aspects. As will be apparent to those skilled in the art, many modifications and exemplifications can be made without departing from its spirit and scope. In addition to those listed herein, functionally equivalent methods and devices within the scope of this disclosure will be apparent to those skilled in the art from the foregoing description. Such variations and embodiments are intended to be within the scope of the appended claims. This disclosure is limited only by the terms of the appended claims, and such claims are limited by the full scope of equivalents to which they are entitled. It should also be understood that the terms used herein are for the purpose of describing only specific examples and are not intended to be limiting.

[0129] Regarding the use of substantially any plural and / or singular terms herein, those skilled in the art can translate from plural to singular and / or from singular to plural as appropriate for the context and / or application. Various singular / plural substitutions may be explicitly shown herein for clarity.

[0130] One of ordinary skill in the art will understand that common terms used herein, especially in the appended claims (e.g., the body of the appended claims), are generally intended to be terms in a "broad sense" (e.g., the term "comprising" should be construed as "comprising but not limited to", the term "having" should be construed as "having at least", the term "including" should be construed as "including but not limited to", etc.).

[0131] If a specific number of introduced claims is intended, such intent will be explicitly recited in the claims, and one of ordinary skill in the art will further understand that if there is no such recitation, such intent does not exist. For example, for clarity, the following appended claims may include the use of introductory phrases such as "at least one" and "one or more" to introduce the claim recitations. However, the use of such phrases should not be construed to limit the recitation of a particular claim that includes such introduced claim recitation to an example that includes only one such recitation, even if the claim recitation of a particular claim that includes such introduced claim recitation is introduced by "a" or "an" and the same claim includes ambiguous items such as "one or more" or "at least one or more" (e.g., "a" and / or "an" should be construed to mean "at least one or more"). Further, even if a specific number of introduced claim references is explicitly recited, one of ordinary skill in the art will recognize that such reference should be construed to mean at least the number recited (e.g., a bare reference of "two references" without other modifiers means at least two references, or two or more references).

[0132] Furthermore, when a convention similar to “at least one of A, B, and C, etc.” is applied, generally, such a configuration is intended to be understood by those skilled in the art (for example, “a system having at least one of A, B, and C” includes, but is not limited to, a system having A alone, B alone, C alone, A and B alone, A and B together, A and C together, A and C together, B and C together, and / or A, B, and C together, etc.). When a convention similar to “at least one of A, B, or C, etc.” is used, generally, such a configuration is intended to be understood by those skilled in the art (for example, “a system having at least one of A, B, or C” includes, but is not limited to, a system having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Furthermore, it should be further understood by those skilled in the art that in any of the embodiments, claims, or drawings for carrying out the invention, substantially any discrete words and / or phrases presenting two or more alternative terms are contemplated to include one of the terms, any of the terms, or both of the terms. For example, the phrase “A or B” is understood to include the possibilities of “A” or “B” or “A and B”.

[0133] As will be understood by those skilled in the art, for any and all purposes, including providing the described explanations, all ranges disclosed herein include any and all possible sub-ranges and combinations of sub-ranges. Any of the recited ranges can be readily recognized as fully describing and enabling the same range to be broken down into at least equal halves, thirds, fourths, fifths, tenths, etc. By way of non-limiting example, each range discussed herein can be readily broken down into lower thirds, middle thirds, upper thirds, etc. Also, as will be understood by those skilled in the art, all language such as "maximum," "at least," "greater than," "less than," etc. includes the recited numbers and refers to ranges that can later be broken down into sub-ranges as described above. Finally, as will be understood by those skilled in the art, ranges include their respective individual members. Thus, for example, a group having 1 to 3 items refers to a group having 1, 2, or 3 items. Similarly, a group having 1 to 5 items refers to a group having 1, 2, 3, 4, or 5 items, etc.

[0134] As will be understood by those skilled in the art, for any and all purposes, all references to order (e.g., first, second, third) are used only for identification purposes to aid the reader's understanding of the invention and do not, in particular, create limitations with respect to the position, orientation, or use of the invention. Such descriptions of order do not limit the scope of the disclosure in any way, and elements can be claimed in any order, with such reference, without departing from the disclosure.

[0135] Although 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 only and are not intended to be limiting, and the true scope and spirit are indicated by the following claims.

Claims

**Claim 1** A flexible and expandable web including an expandable chamber formed of a plurality of expandable and contractible cavities having an inlet for receiving fluid and configured to seal the fluid therein, wherein when the expandable chamber expands, the expandable web structure has an outer surface with a first undulation including a plurality of peaks and valleys, the peaks being configured to define a first virtual tangent plane connecting the plurality of peaks, and the inlet being further configured such that the fluid flows out of the expandable chamber, the flexible and expandable web, and A flexible first outer layer attached to the peaks of the outer surface with the first undulation and separated from the valleys, wherein when the chamber expands, the first outer layer extends along the first virtual tangent plane, bridging the valleys of the outer surface with the first undulation, and when the chamber expands, the attached first outer layer and the expandable web cooperate to form a frame structure having a bending stiffness significantly improved compared to the bending stiffness generated in the expandable web structure where the first outer layer is not attached, the flexible first outer layer, and A protective packaging web comprising. **Claim 2** The expandable web structure includes first and second overlapping chamber layers having a seal pattern therebetween that provides the outer surface with the first undulation when the expandable chamber expands, the protective packaging web of claim 1. **Claim 3** The first chamber layer defines the outer surface with the first undulation, and the second chamber layer is a second outer layer that cooperates with the first outer layer and the first chamber layer to provide the frame structure, the protective packaging web of claim 2. **Claim 4** The second chamber layer is configured to define an outer surface with a second undulation when the expandable chamber expands on a major side opposite to the outer surface with the first undulation, the protective packaging web of claim 2. **Claim 5** Further comprising a flexible second outer layer attached to the ridges on the outer surface with the first undulation including the plurality of ridges and valleys, and separated from the valleys, wherein the plurality of ridges on the outer surface with the second undulation define a second virtual contact surface in contact with the plurality of ridges, and when the inflatable chamber expands, the second outer layer extends along the second virtual contact surface, bridging the valleys on the outer surface with the second undulation, thereby cooperating to increase the bending stiffness of the frame structure. The protective packaging web according to claim 4.

6. The protective packaging web according to claim 1, wherein the distance along the outer surface with the first undulation between the ridges to which the first outer layer is attached is greater than the distance along the first outer layer between the ridges to which the first outer layer is attached.

7. The protective packaging web according to claim 1, wherein the protective packaging web having the inflated inflatable chamber has a thick plate configuration that is naturally biased to maintain a flat configuration in which the first and second outer layers extend substantially flat.

8. The protective packaging web according to claim 1, wherein the ridges include a number of ridges arranged in a 2D pattern on the outer surface with the first undulation.

9. The inflatable chamber includes a plurality of protruding structures, each of the protruding structures including a base perimeter surrounding an open base region and an extension surface protruding from a flat portion defined by the flexible and inflatable web in a substantially flat state, the protruding structure having a surface area larger than the open base region, forming a series of cavities, and each of the plurality of protruding structures including the inflation port that allows the plurality of cavities to expand through the inflation port. The protective packaging web according to claim 1.

10. The protective packaging web according to claim 9, wherein the surface of the protruding structure is at least partially formed in a plastically stretched portion of the flexible and inflatable web.

11. The protective packaging web according to claim 1, wherein each of the inflatable chambers extends along the flexible and inflatable web at an angle not perpendicular to the longitudinal edge of the flexible and inflatable web.

12. The protective packaging web according to claim 1, wherein the flexible and inflatable web and the flexible first outer layer form a second flexible chamber having an injection port between the flexible and inflatable web and the flexible first outer layer, receiving fluid from the injection port and sealing the fluid inside.

13. A protective packaging web according to claim 12, further comprising one or more discharge elements between the flexible and expandable web and the flexible first outer layer, configured to enable removal of fluid from one or more second expandable chambers.

14. The protective packaging web according to claim 1, wherein the flexible first outer layer extends along the length of the flexible and expandable web.

15. The protective packaging web according to claim 1, further having an inflation region connected to the inlet, the inflation region forming a flow path being formed within the flexible and expandable web, the inlet allowing fluid to flow out of the expandable chamber and into the inflation region and back into the expandable chamber, the expandable chamber being foldable in a non-inflated state and then being able to return to an inflated state.

16. The expandable chamber includes adjacent longitudinal seals, the longitudinal seals closing the inlet and preventing the expandable chamber from expanding or contracting, the protective packaging web according to claim 15.

17. The protective packaging web according to claim 1, wherein the flexible first outer layer is attached to the flexible and expandable web via a heat seal.

18. The protective packaging web according to claim 17, further comprising a heat-resistant material attached to one or more of the flexible first outer layer and the flexible and expandable web, the heat-resistant material preventing the first outer layer from being heat-sealed to the flexible and expandable web at a position where the heat-resistant material is disposed between the flexible first outer layer and the flexible and expandable web.

19. A flexible and expandable web including an expandable chamber formed of a plurality of inflatable and contractible cavities having an inlet, configured to receive fluid from the inlet and seal the fluid therein, the expandable chamber being inflated, the expandable web structure having a first corrugated outer surface including a plurality of peaks and valleys, the peaks defining a first virtual tangent plane connecting the plurality of peaks, providing the flexible and expandable web, and When the expandable chamber expands and the injection port is not sealed, the first outer layer is separated from the trough portion, the first outer layer extends along the first virtual contact surface, bridges the trough portion of the outer surface with the first undulation, and when the chamber expands, the attached first outer layer and the expandable web together form a frame structure, and the flexible first outer layer is attached to the peak portion of the outer surface with the first undulation so as to have a significantly increased bending rigidity as compared with the bending rigidity resulting from the expandable web structure to which the first outer layer is not attached. A method for forming an expandable web including the above.

20. The method further includes holding the injection port in a at least partially closed state to hold fluid in the expanded chamber, and while the injection port is held closed, the flexible first outer layer is attached to the peak portion. The method of claim 19.

21. The method of claim 20, wherein the injection port is kept closed by pinching.

22. The method of claim 19, wherein the flexible first outer layer is attached to the peak portion by heat sealing.

23. The method further includes applying a heat-resistant material to one or more of the flexible first outer layer and the flexible and expandable web, and the heat-resistant material prevents the first outer layer from being heat-sealed to the flexible and expandable web at a position where the heat-resistant material is disposed between the flexible first outer layer and the flexible and expandable web. The method of claim 22.

24. The method of claim 19, wherein the outer surface with the first undulation is at least partially formed by a plastically extended portion of the first outer layer.

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