Protective packaging forming device, system including the protective packaging forming device, and method for forming the protective packaging forming device

Abstract

The present disclosure is directed to a web control guide for an inflation and sealing assembly of a protective package forming apparatus for inflating a web material into a chain of inflated cushions. The web control guide is positioned along the material path at a lateral distance from a first compression element and limits a first thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path. The thickness dimension limited by the lateral distance is sufficiently small to prevent lateral movement of the flexible material toward the first compression element to avoid excessive heating of the web material outside the seal zone.

Description

Technical Field

[0001] The present disclosure relates to packaging materials. More particularly, the present disclosure relates to an apparatus and method for manufacturing an inflatable cushion for use as a packaging material.

Background Art

[0002] Various inflated cushions are well known and are used for packaging grocery items. For example, inflated cushions are often used as protective packaging in the same manner as, or instead of, peanut-type foams, crumpled paper, and similar products. Also, for example, foam cushions are often used as protective packaging instead of molded or extruded packaging parts. A typical cushion is one in which two films are sealed together. The seal can be formed while simultaneously inflating to take in air therein, or can be formed to define a film configuration having inflatable chambers prior to inflation. The inflatable chambers can be inflated with air or other gas and are then sealed to suppress or prevent the release of air or gas.

Summary of the Invention

[0003] Embodiments of the present disclosure may include a protective packaging forming apparatus. A protective packaging forming apparatus is disclosed. The apparatus includes a drive that advances a web of flexible material along a longitudinally extending material path. An inflation nozzle directs fluid between overlapping plies of the flexible web in the material path and inflates an inflatable chamber defined between the plies with the fluid. The apparatus includes a heat sealer having first and second opposing compression elements compressed together to compress overlapping plies together at a sealing zone along the material path. A heating element is configured to supply heat to the sealing zone. The compression elements and the heating element are arranged and configured to cooperatively produce sufficient compression and heat in the overlapping plies compressed at the sealing zone to heat seal the overlapping plies together, thereby sealing the inflated inflatable chamber and capturing fluid therein. A web control guide is disposed along the material path laterally spaced from the first compression element and constrains a first thickness of the material path measured in a direction perpendicular to the longitudinal and lateral directions of the material path. The constrained thickness dimension is small enough to prevent lateral movement of the flexible material toward the first compression element to avoid excessive heating of the web outside the sealing zone.

[0004] In some embodiments, an inflation assembly includes a web material director that includes a web director portion that contacts a first surface of the web material and a second web director portion that contacts a second surface of the web material and is opposite the first portion. The inflation nozzle is disposed between the web material director portions and is received within an inflation channel formed between the plies, and is operable to flow fluid into the inflation channel to inflate the chamber. The web material director portions contact the web material upstream of the seal region along the material path and extend transversely of the web material sufficient to engage the inflated portion of the chamber to align the transverse axis of the web material with the axis of the sealing element and the axis of the opposing compression element that seals the overlapping plies together.

Brief Description of the Drawings

[0005]

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[0006] The present disclosure relates to protective packaging and to systems and methods for converting expandable materials into inflatable cushions that can be used as cushioning or protection for the packaging and shipping of merchandise.

[0007] As shown in FIG. 1, a multi-ply flexible web material 100 for an inflatable cushion 121 is provided. The web material extends in a longitudinal direction 109 and a transverse direction 111. The longitudinal direction 109 generally corresponds to the direction in which the web material 100 is supplied onto a path 115 through a forming or inflating device, or the direction in which the web material 100 is removed from or added to a bulk supply of material such as a stack or roll. The transverse direction 111 extends generally orthogonal to the longitudinal direction 109 and along the width W of the web material 100. The web material 100 includes a first film ply 105 having a first longitudinal edge 102 and a second longitudinal edge 104, and a second film ply 107 having a first longitudinal edge 106 and a second longitudinal edge 108. The second film ply 107 overlaps the first film ply 105 and is aligned to be generally coaxial. That is, at least the first longitudinal edges 102, 106 are aligned with each other, and / or the second longitudinal edges 104, 108 are aligned with each other. In some embodiments, the plies can partially overlap inflatable areas in the overlapping region. Accordingly, the web material 100 extends along the thickness of the plies in a thickness direction 113, which is shown in FIG. 1 as extending out of the page. The thickness direction 113 is generally orthogonal to both the longitudinal direction 109 and the transverse direction 111.

[0008] FIG. 1 shows a top view of a web material 100 having first and second plies 105, 107 joined to define a first longitudinal edge 110 and a second longitudinal edge 112 of the web material 100. The first and second plies 105, 107 can be formed from a single sheet of flexible material, a flattened tube of flexible material having one edge slit or open, or two sheets of flexible material that can be sealed along longitudinal edges 104, 108 to define the longitudinal edge 112 of the flexible structure 100. For example, the first and second plies 105, 107 can include a single sheet of flexible material that is folded to define joined second longitudinal edges 104, 108 (e.g., a “c-fold film”). In a more specific example, edges 104, 108 are c-folded in such an embodiment. Alternatively, for example, the first and second plies 105, 107 can include a tube of flexible material (e.g., a flattened tube) having slits formed along aligned first longitudinal edges 102, 106. Also, for example, the first and second plies 105, 107 can include two independent sheets of flexible material joined, sealed, or otherwise attached together along aligned second longitudinal edges 104, 108.

[0009] In some embodiments, the web plies 105, 107 have a thickness of from about 0.5 mils to 4 mils. In some embodiments, the web plies 105, 107 have a thickness of at least about 1 mil. In some embodiments, the web plies 105, 107 can have a thickness between about 2 μm and about 3 μm.

[0010] In some embodiments, the web plies 105, 107 are made from a co-extruded material that includes nylon. For example, the web plies 105, 107 may be made from polyethylene and nylon. The material including nylon functions as a fluid barrier and retains air or other desired fluids over the shoe shipping and storage cycles. Other suitable materials and structures can be used.

[0011] The multi-ply web 100 may be made from a single-layer or multi-layer polymer film material. Each ply may be made from a single-layer or multi-layer film. The single-layer film is typically made of polyethylene, but other suitable polymers may be used. One or more layers of the multi-layer film embodiment may include polymers of different compositions. In some embodiments, the disclosed layers may be selected from ethylene, amide, or vinyl polymers, copolymers, and combinations thereof. The disclosed polymers may be polar or non-polar. The disclosed ethylene polymers may be substantially non-polar forms of polyethylene. In many cases, the ethylene polymer may be a polyolefin made from the copolymerization of ethylene and another olefin monomer, such as an α-olefin. The ethylene polymer may be selected from low, medium, and high density polyethylene, or combinations thereof. In some cases, the densities of the various polyethylenes may vary, but in many cases, the density of low density polyethylene may be, for example, about 0.905 g / cm3 or less to about 0.930 g / cm3, the density of medium density polyethylene may be, for example, about 0.930 g / cm3 to about 0.940 g / cm3, and the density of high density polyethylene may be, for example, about 0.940 g / cm3 to about 0.965 g / cm3 or more. Other suitable densities of the various polyethylenes may be used. The ethylene polymer may be selected from linear density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), and high density polyethylene (HDPE), and mixtures thereof, and metallocene such as metallocene LLDPE (mLLDPE) or metallocene MDPE (mMDPE). Other suitable materials and structures may be used, such as heat sealable and inflatable materials.For example, composites of materials can be used. The disclosed web material 100 can be wound around a hollow tube, a solid core, or folded within a fan folded box, or take another desired form for storage and shipping. Other suitable web materials can alternatively be used and preferably may include a seal layer for heat sealing to another similar layer.

[0012] In some embodiments, the polar polymer may be non-polar polyethylene that can be deformed to impart polar characteristics. In other embodiments, the polar polymer is an ionomer (e.g., a copolymer of ethylene and methacrylic acid, E / MAA), an EVA copolymer with a high vinyl acetate content, or other polymers having polar characteristics. In one embodiment, the modified polyethylene may be anhydride modified polyethylene. In certain embodiments, maleic anhydride is grafted onto an olefin polymer or copolymer. The modified polyethylene polymer may react rapidly when coextruded with polyamide and other ethylene-containing polymers (e.g., EVOH). In some cases, a layer or sublayer composed of the deformed polyethylene may form covalent bonds, hydrogen bonds, and / or dipole-dipole interactions with other layers or sublayers, such as a sublayer or layer that constitutes a barrier layer. In many embodiments, the modification of the polyethylene polymer can increase the number of atoms on the polyethylene available for bonding. For example, the modification of polyethylene with maleic anhydride adds an acetyl group to the polyethylene, and this acetyl group can then bond to a polar group in the barrier layer, such as a hydrogen atom on the nylon backbone. Also, the modified polyethylene can form bonds with other groups on the nylon backbone and polar groups in other barrier layers, such as alcohol groups on EVOH.In some embodiments, the modified polyethylene may form chain entanglements and / or van der Waals interactions with unmodified polyethylene.

[0013] The layers of ply 105, 107 may be adhered, for example, by tie layers or attached together in other ways. In other embodiments, one or more of ply 105, 107 are monolayer materials such as, for example, polyethylene layers.

[0014] Also, a mixture of ethylene and other molecules may be used. For example, ethylene vinyl alcohol (EVOH) is a copolymer of ethylene and vinyl alcohol. EVOH has polarity and can assist in the formation of a gas barrier. EVOH can be prepared by polymerizing ethylene and vinyl acetate to obtain an ethylene vinyl acetate (EVA) copolymer and then hydrolyzing it. EVOH can be obtained by saponifying an ethylene-vinyl acetate copolymer. The ethylene-vinyl acetate copolymer can be produced by known polymerizations such as solution polymerization, suspension polymerization, emulsion polymerization, etc., and the saponification of the ethylene-vinyl acetate copolymer can also be carried out by known methods. Generally, EVA resins are produced in high-pressure autoclaves or tubular processes.

[0015] Polyamide is a high molecular weight polymer having amide linkages along its molecular chain structure. Polyamide is a polar polymer. Nylon polyamide, which is a synthetic polyamide, has favorable physical properties such as high strength, rigidity, abrasion resistance, chemical resistance, and low permeability to gases such as oxygen.

[0016] As shown in FIG. 1, the web material 100 can include a series of transverse seals 118 disposed along the longitudinal extent of the web material 100. Each transverse seal 118 extends from the longitudinal edge 112 towards the inflation channel 114. In the illustrated embodiment, the inflation channel 114 extends along the first longitudinal edge 110 on the opposite side of the second longitudinal edge 112, and the transverse seals 118 extend from the longitudinal edge 112 towards the first longitudinal edge 110. In some embodiments, the flexible structure 100 can include inflation channels 114 located elsewhere in relation to the (one or more) longitudinal edges 112 and / or 110. For example, the inflation channels can extend along the length of the structure 100 at an intermediate position (e.g., midpoint) between the (one or more) longitudinal edges 112 and / or 110. In some embodiments, the flexible structure 100 can additionally or alternatively include inflation channels 114 along the second longitudinal edge 112. In the illustrated embodiment, each transverse seal 118 has a first end 122 proximate to the second longitudinal edge 112 and a second end 124 spaced a transverse width 103 from the first longitudinal edge 110 of the web material 100. The inflatable chamber 120 is defined within the boundary formed by the seal or fold at the longitudinal edge 112 and a pair of adjacent transverse seals 118. When the chamber inflates and the plies 105, 107 of the web material 100 are sealed together to form a continuous longitudinal seal 170 (shown as a phantom line in FIG. 1), for example, at a seal closing the inlet channels 125, the web material forms an inflated cushion 121. The web can be converted to have different seal patterns between the first ply and the second ply, for example, to provide different types of void fill or protective packaging cushions. In some embodiments, the inflatable chamber is provided, for example, without internal seals.In some embodiments, the converted web has a seal pattern lacking internal seals and has a large aspect ratio to provide larger inflatable pillows.

[0017] Each transverse seal 118 of the embodiment of FIG. 1 is substantially linear and extends substantially perpendicular to the second longitudinal edge 112 in the transverse direction 111. In other embodiments, other arrangements of the transverse seals 118 can be used. For example, in some embodiments, the transverse seals 118 can have an undulating or zigzag pattern.

[0018] Not only the transverse seals 118, but also the sealed longitudinal edges 110, 112 can be formed by any of a variety of techniques known to those skilled in the art. Such techniques include, but are not limited to, adhesion, friction, welding, fusion, heat sealing, laser sealing, and ultrasonic welding.

[0019] An inflation region such as a closed path that can become the longitudinal inflation channel 114 is provided. Alternatively, the inflation region can be provided by open transverse edges, along with flaps held over lateral nozzles for blowing gas between the plies 105, 107. As shown in FIG. 1, the longitudinal inflation channel 114 is disposed between the second end 124 of the transverse seal 118 and the first longitudinal edge 110 of the web material. Preferably, the longitudinal inflation channel 114 extends longitudinally along the longitudinal edge 110, and the inflation outlet 116 openings are disposed on at least one end of the longitudinal inflation channel 114. The longitudinal inflation channel 114 has a transverse width 103 corresponding to the transverse width between the longitudinal edge 110 and the second end 124 of the transverse seal 118.

[0020] The longitudinal edges 112 and the transverse seals 118 jointly define the boundaries of the inflatable chambers 120. As shown in FIG. 1, each inflatable chamber 120 is defined between an internal seal 123 and a transverse seal 118 and is in fluid communication with the longitudinal inflation channel 114 via an inlet channel 125 that opens towards the longitudinal inflation channel 114 and allows inflation of the inflatable chamber 120 as will be further described. The inlet channel 125 has a transverse width 119 defined between respective ends 131, 133 of the internal seal 123. The internal seal 123 has transverse ends 142, 144. The transverse end 144 is adjacent to the inflation channel 114 and the transverse end 142 defines the starting point of a first chamber portion 130 located laterally from the inflation channel 114. The inlet channel 125 has a longitudinal length 135 defined between the end of the internal seal 123 adjacent to the transverse seal 118. The seal pattern in the web material 100 can vary. For example, the longitudinal spacing between adjacent transverse seals 118 can be made smaller or larger depending on the desired properties of the finished cushion 121. Making the spacing between the transverse seals 118 smaller can result in a thinner, more flexible cushion 121. A larger spacing between the transverse seals can result in a thicker, relatively less flexible cushion 121 that can provide more cushioning. In some embodiments, the longitudinal spacing between the transverse seals 118 can be made as small as about 1 / 4 or 1 / 2 inch and can be sized up to 1 inch, up to 2 inches, or up to a size greater than 10 inches. Other suitable spacings can alternatively be selected.

[0021] The web material 100 includes a portion 151 that extends from the first longitudinal edge 110 to approximately the longitudinal seal 170. As will be described later, the portion 151 is received within the expansion side gap 211 of the expansion and sealing device 101 formed between the sealer guide member 228 and the compression element. The web material 100 includes a portion 153 where the longitudinal seal 170 is formed. The web includes a portion 157 that is received between the sealer guide member 222 and a part of the compression element 204. The portion 153 is received between the opposing compression elements 204 and 206 of the heat sealer 202. The web material 100 includes a portion 155 received within a director gap 269 defined by the opposing surfaces 265, 267 of the director portions 264, 266 of the web material director 261, which aligns and supports the web material 100 when the web material 100 is expanded. The director portions 264, 266 face each other on opposite sides of the thickness of the web material 100. In this embodiment, the director portions 264, 266 extend laterally beyond the end of the inlet channel 125. The portions 151, 153, 155, 157 extend in the longitudinal direction of the web 100. Also, the portion 155 is received within a web control gap 201 defined between the compression element 204 and the web control guide 212 at different longitudinal positions of the expansion and sealing device 101, and is configured to prevent lateral movement of the web material 100 when the web is sealed by the heat sealer 202 described later. The expansion nozzle 240 inserted into the expansion channel 114 can also prevent the web material 100 from moving laterally when the web material 100 is sealed.

[0022] In the embodiment of FIG. 1, the flexible structure 100 includes internal seals 123, 128 formed in the interior portion of the inflatable chamber 120. The internal seals 123, 128 are longitudinally spaced from the lateral seal 118. In other embodiments, the internal seals 128 can be adjacent or connected to their respective lateral seals 118 and extend toward or within their respective (one or more) inflatable chambers 120. The internal seal 128 defines perpendicularly lower regions of the inflatable chamber 120 corresponding to a smaller width or a restriction in the width of the chamber, thereby creating bendable regions that can be aligned to create bend lines, thereby increasing the flexibility of the web material 100 so that it can be more easily bent or folded. Such flexibility allows the web material 100 to wrap around objects of regular and irregular shapes. The internal seals 123, 128, in conjunction with the lateral seal 118, generally define a chamber portion 130 having a greater inflation height than other portions of the inflatable chamber 120, the chamber portion 130 being a billowed chamber portion within the inflatable chamber 120. The chamber portion 130 is in fluid communication with an adjacent chamber portion 130 via an in-chamber passage 140 and is also in fluid communication with the inflation channel 114 via an inlet channel 125. The internal seal 128 sandwiches the plies 105, 107 to reduce the height of the chamber portion 130 and forms hinges that allow the inflated cushion 121 to conform to an object. The internal seal 128 can be of any shape (e.g., rectangular, circular, oval, or having any other regular or irregular shape as shown) or size. According to some embodiments, the lateral seal 118 is continuous without interruption such as from the internal seal 128 and the like.

[0023] In the embodiment shown in FIG. 1, the web material 100 includes a weakened portion 126 (e.g., a weakened line such as perforation lines) that is disposed along a longitudinal extent of the web material 100 and extends across the first and second plies of the web material 100. Each weakened portion 126 extends from the second longitudinal edge 112 toward the first longitudinal edge 110, for example, partially or entirely along the length of the transverse seal 118. In the illustrated embodiment, the weakened portion 126 is longitudinally offset by a distance 117 from adjacent transverse seals having an inflatable chamber 120 therebetween to form several inflatable cushions 121 that can be separated along the line of the weakened portion 126. In other embodiments, the weakened portion can extend through a portion of the transverse seal 118. In the illustrated embodiment, the weakened portion 126 is in the form of a transverse weakened line, and each transverse weakened line of the flexible structure 100 is disposed between a pair of adjacent inflatable chambers 120. For example, as depicted in FIG. 1, each line of the weakened portion 126 is disposed between two adjacent transverse seals 118 and between two adjacent inflatable chambers 120. The transverse weakened line 126 facilitates separation of the adjacent inflatable cushions 121. In some embodiments, a thicker transverse seal 118 can be used, which defines the transverse seal portion, and the weakened portion 126 can be provided along at least a portion of the transverse seal portion of the flexible structure 100.

[0024] The weakened portion 126 can be provided in various configurations known to those skilled in the art. For example, in the embodiment of FIG. 1, the weakened portion 126 is provided as a transverse weakened line 126 including a row of perforations, and the row of perforations includes alternating lands and slits spaced along the transverse extent of the row. The lands and slits can occur at regular or irregular intervals along the transverse extent of the row. The lands form small connections across the weakened portion 126. Alternatively, in some embodiments, the weakened portion 126 can include score lines formed in the flexible structure 100 and the like.

[0025] The weakened line 126 can be formed by various techniques known to those skilled in the art. Such techniques include cutting (e.g., techniques using cutting or toothed elements such as bars, blades, blocks, rollers, wheels, etc.) and / or scoring (e.g., electromagnetic (e.g., laser) scoring and mechanical scoring, etc., techniques that reduce the strength or thickness of the material in the first and second plies), but are not limited thereto.

[0026] Preferably, the lateral width 129 of the inflatable chamber 120 is typically less than 50 inches. In some embodiments, the lateral width 129 is greater than 10 inches. In some embodiments, the lateral width 129 is greater than 12 inches. In some embodiments, the lateral width 129 is less than 10 inches. In some embodiments, the lateral width 129 is less than 15 inches. In some embodiments, the lateral width 129 is less than 48 inches. In one embodiment, the lateral width 129 is about 17 inches. In one embodiment, the lateral width 129 is at least 3 inches. Other embodiments may have different lateral widths, as desired. In some embodiments, the longitudinal length 127 between the weakened portions 126 is less than about 48 inches. In some embodiments, the length 127 is at least about 2 inches. In some embodiments, the length 127 is greater than 5 inches. In some embodiments, the length 127 is greater than 6 inches. In some embodiments, the length 127 is greater than 10 inches. In some embodiments, the length 127 is less than 30 inches. Additionally, the inflation height of the inflation chamber 120 can be from at least about 1 inch to about 3 inches, and in some cases up to about 6 inches. It is understood that other suitable dimensions may be used.

[0027] Next, referring to FIGS. 2-14, an inflation and sealing device 101 is provided for converting a flexible structure 100 of non-expanded material into a series of inflated cushions 121. The non-expanded flexible structure 100 can be a bulk quantity supply of non-expanded material 134. For example, as shown in FIG. 2, the non-expanded flexible structure 100 can be provided as a roll 134 of supply material that can be wound around an inner support tube. In some embodiments, the supply material is wound around a roll having a hollow center. The support tube or hollow center of the roll of material 134 is supported by a supply support element 136 of the inflation and sealing device 101, in this case a roll axle 136. The roll axle 136 accommodates the center or tube of the roll of web material 100. In other embodiments, different structures can be used to support the roll of material, such as a tray, a fixed spindle, or a plurality of rollers, or a supply material of a different configuration (e.g., a folded supply material). FIG. 3 shows the inflation and sealing device 101 with the flexible structure 100, such as the roll 134, not attached to the device. In some embodiments, the non-expanded flexible structure 100 of material is supplied from a folded form, such as a fanfolded configuration.

[0028] Figure 3 shows an embodiment of the inflation and sealing device 101. In Figure 3, various covers 159, 161, and 163 are arranged. Cover 163 hides and protects the rear portion (shown in Figure 5 of the inflation and sealing device 101). Covers 159 and 161 hide and protect a part of the sealing assembly 200 and help define the material path 115 through which the web material 100 travels as it moves within the device 101. The inflation and sealing device 101 includes handling elements, and each of the handling elements includes web-supporting portions. The web-supporting portions support and direct the inflatable web 100 of the material longitudinally 109 along a path (e.g., path 115 in Figure 2). The handling elements can include a supply support element 136 that supports the supply portion 134 of the non-inflated web 100. The inflation and sealing assembly 200 is operable to inflate the web 100 with fluid by guiding the fluid between the overlapped plies 105, 107 of the web 100 and seal the plies 105, 107 together to seal the fluid therein. Two of the web-supporting portions (e.g., the roll shaft 136 and the guide member 138) are arranged relative to each other and the support structure 141 so as to receive different amounts of tension along the transverse direction 111 when the supply material 134 passes from the first web-supporting portion to the second web-supporting portion. The relative positions of the two web-supporting portions create a difference in tension in 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 present disclosure, differential tension can be achieved by providing one or more expansion elements on the guide member 138, as further described below.In some examples, the resulting shape of the guide member 138 can be configured to define a slightly shorter longitudinal movement distance between the first and second adjacent web support portions at one lateral end of the web, as compared to the longitudinal movement distance between the first and second web support portions adjacent to each other at another (e.g., opposite) lateral position of the web, as further described.

[0029] Referring back to FIG. 3, the inflation and sealing device 101 can include a bulk material support 136. The bulk supply 134 of the non-inflated material is supported by the bulk material support 136. In some embodiments, the bulk material support is provided as a tray operable to hold the non-inflated supply 134, which can be provided, for example, by a fixed surface or a plurality of rollers. To hold the roll 134 of material, the tray can be concave around the roll, or the tray can be convex with the roll 134 suspended thereon. The bulk material support 136 can include a plurality of rollers that suspend the supply of the web material 100. The bulk material support 136 can include, for example, a single roller that accommodates the center of the roll 134 of the web material 100, as shown in FIG. 2. In this example, the bulk support is the roll shaft 136 that passes through the core or center of the roll 134 of the material 100. Typically, the core is made of cardboard or other suitable material. The bulk material support 136 rotates about the axis 149.

[0030] The web material 100 is pulled through the inflation and sealing device 101 by the drive device 160. In some embodiments, an intermediate member, such as a guide member 138 (which can include, for example, a fixed rod or rollers), can be disposed between the supply section 134 and the drive section 160. For example, the optional guide member 138 can extend generally perpendicular from the support structure 141. The guide member 138 can be positioned to guide the flexible structure 100 away from the roll 134 of material 100 and along a material path 115 (also referred to as a longitudinal path) along which the material is processed. As shown in FIG. 3, the guide member 138 is disposed between a material support 136 that supports the supplied material and the inflation and sealing components of the inflation and sealing device 101. The guide member 138 can be arranged to route the web material 100 from the supply toward the inflation and sealing assembly 200 such that the web material 100 follows a curved longitudinal path. The guide member 138 can include one or more surfaces that define a web support surface (e.g., a surface that extends along the side of the guide member that bends around the web 100 as it crosses the path 115). In some examples, as further described below, the guide member 138 can include one or more inflation elements. The one or more expansion elements can provide at least a portion of the web support surface of the guide member and can be configured to provide variable tension to the web material 100 at different lateral positions of the web material 100.

[0031] The guide member 138 or a part thereof can be movably coupled to the inflation and sealing device 101 such that when the web material 100 is being pulled out from the roll 134 by the drive device 160, the guide member 138 or its movable part can move (e.g., spin, move, vibrate, etc.) relative to the support structure 141. In some examples, the guide member 138 includes a guide roller, and the guide roller includes a shaft or rod portion 137 and a rotatable or roller portion 139 coaxially coupled to the rod portion 137 such that the roller portion 139 rotates about a common axis 148 of the rod portion and the roller portion. The roller portion 139 supports the web 100 and provides a web support surface 150 that moves with the web 100 when the web 100 is being pulled out from the roll 134. The moving web support surface 150 can reduce or eliminate sliding friction between the guide member 138 and the web 100. However, in other embodiments, a guide member having a fixed web support surface 150 may be used. For example, the guide member can include a rod similar to the shaft 137 that does not have a rotatable portion 139. A low-friction material such as polytetrafluoroethylene (PTFE) can be provided on at least a part of the web support surface 150 of the non-rotatable rod (e.g., in the form of a coating or a strip of adhered material) to reduce sliding friction. In still other embodiments, the non-rotatable part or rod of the guide member and the rotatable part (e.g., a roller) of the guide member may not be in the same plane. For example, only the rotating part of the guide member 138 may be the expansion element 152. The (one or more) web support surfaces of the guide member that do not rotate when the web is moving over the guide member can be coated with a (one or more) friction-reducing material or provided in other ways. In some embodiments, the guide member 138 can be additionally or alternatively coupled to the inflation and sealing device 101 such that it moves in a direction perpendicular to the longitudinal path 115 along which the supply material moves.

[0032] In the embodiments shown, the guide member 138 according to the present disclosure includes one or more extension elements 152, as further described below. In some embodiments, the extension element 152 provides some or all of the web support surface 150 of the guide member 138. According to the principles of the present disclosure, the guide member 138 can be configured to control the web material 100 so as to prevent or reduce the sagging of the web material 100 between the roll 134 and the inflation nozzle 240 of the inflation and sealing device 101.

[0033] In various embodiments, the stock material (e.g., web material 100) can proceed downstream from a supply of material such as roll 134 without engaging a guide roll, but instead can proceed directly into the inflation and sealing assembly 200. 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 to guide the web material 100 toward a sealing zone 276 that can form part of the sealing assembly 200, other suitable structures can be utilized. The sealing zone 276 can be a pinch zone where the plies 105, 107 of the web material are sandwiched or compressed and simultaneously heated so that they fuse together. In the sealing zone 276, an inflation fluid can also be supplied. As shown, the web material 100 can be subject to sag, bunch up, drift along the guide roller 138, misalignment in relation to the sealing zone 276, alternating tension and slack, or other variations in delivery, so the inflation and sealing assembly 200 may require suitable adjustability to compensate for these variations.

[0034] The web material 100 is inflated by the drive device 160 and advanced through the sealing assembly 200. The inflation and sealing assembly 200 can incorporate the drive device 160, or the two systems can operate independently. The drive device 160 includes one or more devices operable to move the flexible structure 100 through the inflation / sealing device 101. In the illustrated embodiment, the drive device 160 includes a backing element such as a backing wheel 214 driven by a motor 154 via a belt 158 (see, for example, FIGS. 4 and 5). In other embodiments, the drive unit 160 can include different rollers, wheels, or drums, or two or more of the same. In other embodiments, the backing element can be stationary. In some embodiments, the drive device 160 can include a belt drive device, 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 / sealing device 101. In other embodiments, the belt moves the web material 100 along the material path, and one or more rollers follow while being driven 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 inflation / sealing device 101 along the material path 115. In some embodiments, various belts, drums, or rollers are driven by a single motor and can be connected to other belts, pulleys, or gears to transmit rotational motion to the entire connected drive unit. In other embodiments, the belts, drums, or rollers can be driven by individual motors or servos.

[0035] For example, in various embodiments, the drive apparatus includes one or more motor-driven rollers operable to drive the flexible material 100 in a downstream direction along the material path 115. One or more of the rollers or drums can be connected to a drive motor 154 such that the one or more rollers drive the system. This embodiment is beltless. According to various embodiments, the drive section 160 drives the web material 100 without the belt contacting the flexible structure. In another example, the system has a belt that drives the rollers without contacting the web material 100. In another example, the system has a belt on some of the drive elements but not on others. In another example, the system can have belts interwoven throughout the rollers that allow the material to be driven through the system by the belts.

[0036] The inflation and sealing device 101 includes an inflation and sealing assembly 200. Preferably, the inflation and sealing assembly 200 is configured to continuously inflate as the web material 100 is unwound from the roll 134. The roll 134 preferably consists of a plurality of inflatable chambers 120 arranged in series, for example in a chain-like manner. To initiate the production of the inflation cushion 121 from the web material 100, the inflation outlet 116 of the web material 100 is inserted into the inflation assembly, such as an elongate guide 240 having a length for guiding the web material through the inflation and sealing device 101 into the inflation channel 114. The width of the inflation channel 114 can preferably be selected to fit around the nozzle to allow it to slide over the nozzle and for the fluid to flow into the inflatable chamber 120. In this embodiment, the elongate guide is also the inflation nozzle 240 and is advanced along the material path 115. The nozzle 240 has a longitudinal portion, which includes one or more of the nozzle base 244, the flexible portion 242a, and / or the tip 242. The longitudinal portion can assist in guiding the flexible structure 100 into the sealing zone 276. At the same time, the nozzle 240 can inflate the flexible structure through one or more fluid outlets 246a, b. In this embodiment, the fluid outlets 246a, b are openings in the nozzle 240. The one or more outlets 246a, b exit from the inflation channel through one or more of the nozzle base 244, the flexible portion 242a, or the tip 242. The tip 242 includes a terminal portion 243 that can function as a guide for initiating the guidance of the nozzle 240 into the inflation channel 114. The terminal portion 243 is a hemispherical plug in the illustrated embodiment, but can be of other shapes. In the illustrated embodiment, preferably, the web material 100 is advanced onto the inflation nozzle 240 with the inflatable chamber 120 extending laterally with respect to the inflation nozzle 240 and the side outlets 246a, b (most clearly seen in FIGS. 4, 6, 12, and 13).Side outlets 246a, b direct fluid transverse to nozzle base 244 into expandable chamber 120 to expand expandable chamber 120 as web material 100 travels longitudinally along material path 115. In other embodiments, outlets 246a, b direct fluid in other directions relative to nozzle base 244. Expansion nozzle 240 inserts fluid, such as pressurized air, through the nozzle outlet into unexpanded web material 100 to expand the material into expansion cushion 121. Expansion nozzle 240 can include a nozzle expansion channel that fluidly connects a fluid source entering at the fluid inlet to the nozzle outlet (e.g., side outlets 246a, b). In other configurations, it is understood that the fluid can be other suitable pressurized gas, foam, or liquid. The expanded web material 100 is then sealed by sealing assembly 200 at sealing zone 276 to form a chain of expanded cushions 121. Typically, the nozzle has an outer diameter of about 1 / 4 inch to 1 / 2 inch. In this embodiment, the outer diameter of the nozzle is about 3 / 16 inch. Other suitable nozzle diameters can alternatively be selected.

[0037] Side expansion region 168 (shown in FIG. 2) is shown as a portion of the expansion and sealing assembly along path 115 adjacent to side outlets 246a, b, in which fluid from side outlets 246a, b can expand expandable chamber 120. In some embodiments, expansion region 168 is the region disposed between nozzle tip 242 and sealing zone 276. Web material 100 is inserted around expansion nozzle 240 at nozzle tip portion 242, which is disposed at the foremost end of expansion nozzle 240.

[0038] The expansion nozzle 240 can be at least partially flexible. As shown in FIG. 3, the expansion nozzle 240 includes a tip 242 having a flexible portion 242a that enables the nozzle 240 to adapt in the direction of the web material 100 when the structure is supplied toward and onto the nozzle 240, thereby enabling the nozzle 240 to compensate for or be operable to adapt to variations in the supply angle, direction, and other variations encountered when the web material 100 is being supplied toward and onto the nozzle 240. In some examples, as described above, the guide roller 138 can be laterally movable relative to the sealing assembly 200 to adjust or eliminate variations in the delivery of the supplied material.

[0039] As shown in FIGS. 4, 6 - 9, and 12 - 13, the side outlets 246a, b can extend longitudinally along the nozzle base 244 at a longitudinal distance from the nozzle tip 242. In various embodiments, the side outlets 246a, b originate proximate to, or in some configurations overlapping, the sealer assembly such that the side outlets 246a, b continue to expand the expandable chamber 120 almost until just prior to sealing. This can maximize the amount of fluid inserted into the expandable chamber 120 prior to sealing and minimize the amount of dead chambers, i.e., chambers that do not have a sufficient amount of fluid. However, in other embodiments, the outlets 246a, b can extend downstream beyond the entrance to the sealing zone 276. The start of the web is upstream and flows downstream as it is expanded, sealed, cooled, and removed from the expansion and sealing apparatus 101.

[0040] The length of the side outlet 246a can be a slot having a length that extends a portion of the expansion nozzle 240 between the tip 242 and the sealing zone 276. In one example, the length of the slot can be less than half the distance from the tip 242 to the sealing zone 276. In another embodiment, the length of the slot can be greater than half the distance from the tip 242 to the sealing zone 276. In another embodiment, the length of the slot can be approximately half the distance from the tip 242 to the sealing zone 276. The side outlet 246a can have a length of at least about 30% of the length of the expansion nozzle 240, in some embodiments at least about 50% of the length of the expansion nozzle 240, or about 80% of the length of the expansion nozzle 240, although other relative sizes can be used. The side outlets 246a, b discharge fluid laterally from the sides of the nozzle base 244 with respect to the expansion nozzle 240 through the respective inlet channels 125 of the expandable chamber 120 to expand the expansion chamber 120. The tip 242 of the expansion nozzle 240 is used to pry apart and separate the plies 105, 107 in the expansion channel 114 as the material is pressed onto the tip 242. In some embodiments, a longitudinal outlet can be provided in addition to or in the absence of side outlets, such as side outlets 246a, b that can run longitudinally along the nozzle wall of the nozzle base 244 of the expansion nozzle 240 downstream of the longitudinal outlet.

[0041] Fluids such as air can be supplied to the expansion and sealing device 101 by external devices such as air compressors, blowers, house air systems, and foaming systems. In the illustrated embodiment, the fluid is supplied to the expansion and sealing device 101 via a fluid coupling 172. The fluid is then directed to the nozzle 240 via internal conduits such as pipes or tubes (not shown). The flow rate of the fluid is typically about 2 - 20 cubic feet per minute (CFM). However, much higher flow rates can be used, for example, if a higher flow rate fluid source is used, the flow rate may exceed 100 cfm. In other embodiments, the expansion and sealing device 101 can include an internal fluid source such as a blower or a compressor.

[0042] Although various examples are described and illustrated herein, these examples are not to be limiting, and it is to be understood that the nozzle 240 and the expansion assembly can be configured according to any known embodiment or a developed embodiment that can benefit from the disclosure herein, such that those skilled in the art can apply based on the disclosure herein.

[0043] As shown in FIGS. 3, 4, 6, and 12-14, the inflation and sealing device 101 includes a web material director 261 having a length in the longitudinal direction 109 of the material path 115 and a pair of director portions 264, 266 arranged longitudinally with respect to a web control guide 212 (described later). The director portions 264, 266 orient the transverse dimension of the web material 100 within the material path 115 as the web material 100 passes over the inflation nozzle 240. The director portions 264, 266 orient the inlet channel 125 to the outlets 246a, b of the nozzle 240. The director portions 264, 266 extend from the support structure 141 by a transverse distance 271 (see FIG. 14) sufficient to engage the inflatable portion of the web material 100 when it expands, before the web material 100 is sealed. As shown, the director portions 264, 266 extend perpendicularly from the support structure 141, but in other embodiments, the director portions can extend at an angle that is not perpendicular to the support structure. The web material 100 passes between the director portions 264, 266 as it moves longitudinally through the inflation and sealing device 101.

[0044] The director portions 264, 266 include leading ramp faces 273, 275. The leading ramp faces 273, 275 are tapered in the longitudinal direction 109 and inclined with respect to each other such that the distance between them gradually narrows as the web material 100 first enters between the director portions 264, 266 and then passes therethrough in the longitudinal direction 109. The web material director 261 includes an exit ramp face 279 that is inclined so as to be away from the web material 100 when exiting between the director portions 264, 266. The director portions 264, 266 include transverse ramp faces 281, 283. The transverse ramp faces 281, 283 are tapered in the transverse direction 111 and inclined with respect to each other such that the director gap 269 gradually narrows or widens with respect to the transverse portion of the web 100. The transverse inclined faces 281, 283 thereby form a longitudinal trough 282 that receives a portion of the web material 100. In this embodiment, as shown in FIG. 14, the chamber portion 130 closest to the inflation channel 114 is received between the ramp faces 281, 283 to orient the web 100 with respect to the exit 246a within the nozzle 240 and form the sealing assembly 200. The various ramp faces 273, 275, 281, 283 can assist in initially passing the web material 100 through the inflation and sealing device 101. The ramp faces assist in initiating the alignment of the web material when inflation is initiated, gradually guiding the material 100 to an aligned position to facilitate the sealing of the plies 105, 107, and allowing it to pass through the inflation and sealing device 101.

[0045] In the illustrated embodiment, the nozzle 240 is disposed between the director portions 264, 266. The opposing surfaces 265, 267 are disposed equidistant from the centerline of the nozzle 240. In other embodiments, the centerline of the nozzle 240 may be disposed closer to one of the opposing surfaces 265, 267 and farther from the other of the opposing surfaces 265, 267 such that the nozzle is off-center in the thickness direction with respect to the web material 100.

[0046] When the web material 100 is inflated by the nozzle 240, the plies 105, 107 are pressed against their respective opposing surfaces 265, 267. The opposing surfaces 265, 267 and / or the lamp surfaces impart reactive forces to the inflated portion of the web material 100, thereby maintaining the transverse axis of the web material 100 in alignment with the transverse axis of the components of the sealing assembly 200.

[0047] The director portions 264, 266 align the web material 100 when the web material 100 expands and seals. The director portions 264, 266 have opposing surfaces 265, 267 spaced apart from each other by a director gap 269, respectively, to constrain the thickness of the material path 115. In this embodiment, the director gap 269 is larger than the height of the expanded inlet channel 125, as shown in FIG. 14. In other embodiments, the director gap can be smaller than the height of the expanded inlet channel 125 (when the channel 125 is not constrained). In other embodiments, the director gap 269 is the same size as the height of the expanded inlet channel 125. The director gap 269 can be selected according to the characteristics of the web material 100. For example, the longitudinal spacing between the lateral seals 118 can affect the height or thickness dimension of the expanded chambers 120, chamber portions 130, and / or inlet channel 125. A relatively wide longitudinal spacing between the lateral seals 118 can result in a relatively thick expansion cushion 121 in the thickness direction 113. Similarly, a close longitudinal spacing between the lateral seals 118 results in a thinner expansion cushion in the thickness direction 113. Similarly, the height of the expansion channel 114 during expansion can be affected by the lateral width of the expansion channel from the longitudinal edge 110 to the end of the inner seal 123. The director gap 269 can be appropriately selected to accommodate a thicker or thinner cushion 121 based on the longitudinal spacing between the lateral seals 118. In this embodiment, the director gap 269 is smaller than the outer diameter of the nozzle 240. In this embodiment, the director gap is larger than the height of the expanded inlet channel 125, but is small enough to align the inlet channel 125 with the outlet 246a and orient the remaining portion of the web 100 when pressurized. As shown in FIG. 14, the opposing surfaces 265, 267 extend laterally from the outer surface of the nozzle 240 at the opening 246a to the narrowest portion of the longitudinal trough 282 formed by the lateral ramp surfaces 281, 283, and to the distance 229 to the widest portion of the longitudinal trough 282, up to the director gap width 227.In this embodiment, the director gap width 227 and the distance 229 are such that the lateral edge 142 of the inner seal 123 is located at substantially the same lateral position as the narrowest part of the trough 282. Thus, the chamber portion 130 closest to the director gap 114 in the lateral direction is received in the longitudinal trough 282, whereby the web material is oriented as it rides on the trough 282. In this embodiment, the ratio of the director gap width 227 to the director gap 269 is about 10:1. In other embodiments, the ratio is at least 5:1, 8:1, or most preferably 9:1 to 11:1. In some embodiments, the ratio can be up to about 15:1. Other suitable ratios can be selected based on the seal pattern in the web material 100. In this embodiment, the director gap 269 is about 1 / 4 inch. In other embodiments, the director gap 269 can be at least 1 / 8, 1 / 2, or 1 inch or more. Other suitable director gaps can be selected as being suitable for the web material 100 used. The director gap 269, the director gap width 227, the dimensions of the longitudinal trough 282, and the ratios therebetween can be selected such that the web material 100 can pass through the web material director 261 without bunching, snagging, wrinkling, twisting, coiling, or sticking.

[0048] The opposing surfaces 265, 267 are, in this embodiment, substantially flat and smooth. The opposing surfaces 265, 267 preferably have a position and spacing sufficient to be oriented parallel to each other or at a slight angle and to the transverse axis of the path 115 as required. In some embodiments, when a curved path is desired in that region, the director gap 269 is curved with the expansion nozzle 240.

[0049] After exiting between the director portions 264, 266, the web material enters the sealing assembly 200, where the plies 105, 107 are sealed to form a continuous longitudinal seal 170, thereby capturing fluid to form the cushion 121. Preferably, the web material 100 continuously advances through the seal assembly along the material path 115, passes through the heat sealer 202 at the seal zone 276, and seals the first and second plies 105, 107 together to form a continuous longitudinal seal 170 along the web material 100. Preferably, the longitudinal seal 170 is disposed at a lateral distance from the first longitudinal edges 102, 106, and most preferably, the longitudinal seal 170 is disposed along each inlet 125 of the inflatable chamber 120.

[0050] The inflation and sealing assembly 200 includes a heat sealer 202 for forming a longitudinal seal 170 in the web material 100 at the seal zone 276 and capturing fluid between the plies 105, 107, thus forming the cushion 121. The heat sealer 202 includes compression elements 204, 206 that oppose each other during compression to compress the overlapping plies 105, 107 together at the seal zone 276. The heat sealer 202 includes a heating element 270 that supplies thermal energy to the seal zone 276. The opposing compression elements 204, 206 and the heating element 270 together produce sufficient compression and heat in the compressed overlapping plies 105, 107 at the sealing zone 276 to thermally seal the overlapping plies 105, 107 together, thereby sealing the inflated inflatable chamber 120 to capture fluid. Other suitable sealers such as ultrasonic welders or adhesive sealers can be used.

[0051] In the illustrated embodiment, the compression element 206 is provided as a rotary sealing element 216. The rotary sealing element 216 is arranged to face a compression element 204 where the compression element 206 contacts one side of the web material 100 (e.g., one of the plies 105, 107) and contacts the opposite side of the web material 100 (e.g., the other of the plies 105, 107) in the sealing zone 276, to form a longitudinal seal 170 for confining inflation gas within the inflatable chamber 120. FIGS. 7-9 are cross-sectional views showing the rotary sealing element 216 having relatively narrow protrusions forming the compression element 206 on its circumference. In FIG. 7, for convenience, the rotary sealing element 216 is shown in a state partially retracted from the compression element 204 relative to the sealing position, as shown, for example, in FIG. 9. Certain components of the inflation and sealing device 101 are visible behind the web material 100. Transverse walls 207, 209 extend inwardly from the protrusions towards the axis of rotation of the sealing element 216. As shown in FIGS. 8-9, the right side portion of the web material 100 is an inflation channel 114 into which the inflation nozzle 240 is inserted. In this embodiment, the inflation nozzle 240 functions as an air injector by discharging air (or other inflation fluid) through one or more outlets 246a, b arranged along the nozzle 240. In other embodiments, an injector separate from the nozzle 240 may be used to inject inflation gas into the inflatable chamber 120. In some embodiments, the sealing element 216 includes a non-stick release coating to prevent adhesion of the web material 100 thereon and reduce friction.

[0052] As shown, heating element 270 is an electrically powered plug or cartridge heater. The heating element 270 can be heated electrically, for example, by providing an electrical resistance that converts electrical energy into thermal energy. The heating element 270 can be powered by direct current or alternating current, which can be single-phase or three-phase power. The heat generated in the heating element can conduct and convect heat from the heating element 270 to the rotating seal element 216 and the compression element 206.

[0053] The heating element 270 can be of any material or design suitable for sealing adjacent plies 105, 107 together. In various embodiments, the heating element 270 can be a resistive wire or foil. The wire or foil is formed and operated under conditions suitable for forming and operating a heating element that enables the heating element 270 to melt, fuse, join, bond, or integrate two plies of flexible material together to seal the plies together, and can be formed from nichrome, iron-chromium-aluminum, cupronickel, or other metals. In some embodiments, the heating element 270 is formed from approximately 80% nickel and 20% chromium that is soft annealed. In other embodiments, the heating element 270 can be a thin-film heating element. The thin-film heating element 270 can be formed from a composite of barium titanate and lead titanate, or other materials suitable for forming and operating a heating element under conditions where the heating element 270 can obtain sufficient heat to seal the plies together.

[0054] In the embodiment shown, the seal element 216 is attached such that its axis is fixed relative to the support structure 141. In other embodiments, it can be attached such that it is positionally variable toward and away from the compression element 204 with manual or mechanical assistance.

[0055] To prevent the combustion of the web material 100, it may be desirable to move the seal element 216 away from the web material 100 and retract it, such as when the operation of the inflation and sealing device 101 is interrupted. As shown in FIG. 5, the position of the seal element 216 can be adjusted to increase or decrease the pressure between the compression element 206 and the compression element 204. For example, the actuator 230 operates a cam 231 via a belt 156. The cam follower 232 rides on the cam 231, and the spring 233 is compressed or decompressed to displace the seal element 216 so as to generate more or less sealing force between the compression elements 204 and 206, respectively. The sealing pressure can be adjusted, for example, to accommodate web materials 100 of different thicknesses, different materials, or different numbers of plies.

[0056] In the illustrated embodiment, the seal element 216 is freewheeling and rotates, for example, by the movement of the web material 100 against which the seal element 216 is pressed. In other embodiments, instead of the freewheeling seal element 216, a motor may be provided for rotating the seal element 216 in conjunction with other drive mechanisms.

[0057] Figure 10 is an exploded view of the sealing element in the inflation and sealing device 101. A high-temperature resistant bearing or bushing 262 fits into the seal element 216. The seal element 216 is held in place by a retainer 272 such as a washer, which is held in place by fasteners 274 such as screws, rivets, bolts, etc. In some embodiments, the seal element 216 can be made of a metal such as aluminum, steel, brass, bronze, or other suitable materials. Thus, the seal element 216 can have an appreciable thermal mass. For example, the seal element 216 can have sufficient thermal mass to maintain a sufficiently consistent temperature to continuously seal the plies 105, 107 as the plies 105, 107 move through the seal zone 276. The bushing 262 is disposed on a shaft 263 that includes an opening suitable for receiving the heating element 270. A temperature sensor 268 such as a thermistor or thermocouple is provided to sense and control the temperature of the heat sealer 202. The temperature of the heat sealer 202 can be controlled to about 100°C to 450°C, preferably 260°C to 310°C, more preferably 280°C to 290°C. According to various embodiments, the heat sealer 202 is heated up to between about 150°C and 250°C. In some embodiments, the heat sealer 202 reaches about 200°C. The peripheral portion of the heat sealer 202 can reach a low temperature between about 50°C and 100°C.

[0058] As shown in FIGS. 7-9, the compression element 204 is disposed on the backing wheel 214. The compression element 204 is an elastic member that extends circumferentially on the backing wheel 214. The backing wheel 214 is driven by the motor 154 as depicted in FIGS. 4 and 5. In other embodiments, the backing wheel can be driven by a free wheel and a drive wheel that frictionally engages the compression element 204. The compression element 204 includes a crown portion 208 for assisting in maintaining a flattened state in the sealing zone 276 when the web material 100 is expanded and fed through the sealing assembly 200. The crown portion 208 has a raised rectangular profile that extends circumferentially from a shoulder portion 210 of the compression element 204. In other embodiments, the crown portion can have other profiles, such as a convex or concave profile. The crown portion 208 has a radius that is greater than the radius of the shoulder portion 210. In the embodiment shown, the compression element 204 includes two shoulder portions 210 and the crown portion 208 is disposed therebetween laterally. In other embodiments, the compression element 204 can have one shoulder portion 210 or can have a flat cross-section that does not have a shoulder portion 210 or a crown portion 208.

[0059] The compression element 204 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 206, improving the seal quality and increasing the seal dwell time. As shown in FIG. 9, when the compression elements 204 and 206 are joined and pressed against each other, the compression element 206 presses on the top portion 208, distorting it into a concave profile that conforms to the convex profile of the compression element 206. Non-limiting examples of the compression element 206 include drums, plates, wheels, boxes, and other surfaces composed of metal or other rigid materials. The backing wheel 214 can have an elastic material applied to one or more of its surfaces so as to function as the compression element 204. For example, the compression element 204 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 204 can be preconfigured as a resilient band and stretched over the backing element. The thickness of the compression element 204 typically ranges from about 1 / 8 inch to about 1 / 4 inch. The elastic material should be selected such that the web material 100 does not stick excessively to the compression element 204. Also, the elastic material needs to be selected so as not to degrade with heat. Suitable elastic materials often have a Shore A hardness of from about 20 durometer to about 95 durometer, typically from about 45 durometer to about 75 durometer, more typically from about 50 durometer to about 70 durometer. For example, a 60 durometer silicone rubber can be used.

[0060] In other embodiments, the compression element 204 can be a non-rotating stationary element. The surface of such a compression element 204 can curve along the material path 115. The apex of the curve can be located at approximately the center of the backing element 214, for example, at the location where the seal element 216 contacts the web material 100. The curved surface of the backing element 214 effectively lengthens the path of the web material 100, which helps 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 120 inflates (due to inflation in the thickness direction of the web material 100). However, since the ends of the web material 100 sealed by the heat sealer 202 do not inflate, the end lengths do not decrease even when the inflatable chamber 120 inflates. As a result, the ends of the web material 100 tend to gather, for example, in an "accordion" shape as the inflatable chamber 120 inflates. The curved surface of the backing element 214 increases the length of the material path 115, which aids in maintaining the flattened state when the web material 100 is inflated and fed through the sealing assembly 200.

[0061] As shown in FIGS. 6 to 9, a seal guide member 222 is provided adjacent to the backing wheel 214. The seal guide member 222 has a guide body 234. The guide body 234 has an intake portion 235 and an exit portion 237. The intake portion 235 has an intake guide surface 223 provided at a distance from a part of the compression member 204 to define an intake gap 213. The exit portion 237 has an exit guide surface 225 provided at a distance from a part of the compression member 204 to define an exit gap 215. In this embodiment, the intake guide surface 223 defines the intake gap 213 between the shoulder 210 of the compression element 204 and the seal guide member 222 upstream of the seal zone 276. In this embodiment, the exit guide surface 225 defines the exit gap 215 between the shoulder 210 of the compression element 204 and the seal guide member 222 downstream of the sealing zone 276. The exit guide surface 225 and the exit gap 215 can be provided in the same manner as the intake guide surface 223 and the intake gap 213. The intake shoulder 236 provides a smooth transition from the intake guide surface 223 to the other part of the guide body 234. The exit shoulder 238 provides a smooth transition from the exit guide surface 225 to the other part of the guide body 234. The seal guide member 222 receives the web material 100 away from the web material director 261 and holds it against the compression member 204. The seal guide member 222 and the compression member 204 are forced to bend in the material path 115 so that the backing wheel 214 can drive the web material 100 along the material path 115.

[0062] As shown in FIG. 6, when the web material 100 passes from the web material director 261 and enters the suction gap 213, the web 100 begins to bend laterally over the crown portion 208 of the compression element 204, creating tension in the web material 100 for alignment for sealing. The suction guide surface 223 holds the web material 100 against the compression element 204 to control and draw the web material 100. In this embodiment, the suction guide surface begins to bend the web material 100 around the compression element 204 upstream of the seal zone 276. In this embodiment, the suction gap 213 and the outlet gap 215 are smaller than the height 219 of the radial wall 221 of the crown portion 208 defined between the shoulder portion 210 and the crown portion 208 of the compression element 204. In this embodiment, the size of the suction gap 213 is selected to press the web material 100 against the crown portion 208 and / or the shoulder portion 210. In other words, the suction guide surface 223 is at a height lower than the crown portion 208, and the crown portion 208 and the suction guide surface 223 preferably both press the inlet channel 125 against the crown portion 208 to cause a lateral bend of the web material 100 around the crown portion 208. Preferably, the height of the suction guide surface 223 on the shoulder portion 210 is at most the height of the inlet channel 125 inflated to the height of the crown portion 208. A low height of the suction guide surface 223 relative to the crown portion 208 can cause a sharp lateral bend in the web material 100. The bending increases friction and creates tightness in the region of the web material leading to the seal zone 276. In some embodiments, the suction guide surface 223 is at a height that does not cause a lateral bend in the web material 100 relative to the compression element 204.

[0063] In other embodiments, the inhalation gap 213 and / or the outlet gap 215 can be the same as the height 219. In other embodiments, the inhalation gap 213 can be larger than the height 219. In this embodiment, the inhalation gap 213 is wider than the height of the expandable inlet channel 125 so that the expandable chamber 120 can continue to receive pressure from the outlets 246a, b. In other embodiments, the inhalation and outlet gaps 213, 215 can be the same size as the height of the expanded inlet channel 125. In other embodiments, the inlet gap 213 can be smaller than the height of the inlet channel 125 such that the gap limits the height of the inlet channel 125 and further presses the expanded web material against the compression element 204. In embodiments where the height of the inlet channel 125 is smaller than the inhalation gap 213, the inlet channel 125 can continue to receive pressure from the outlets 246a, b.

[0064] The movement from the inhalation gap 213 and the outlet gap 215 to the web control surface 220 is provided by the inlet ramp 224 and the outlet ramp 226, respectively. The inlet ramp 224 is disposed upstream of the contact point between the compression elements 204, 206 and aligns and constrains the web material 100. The inlet ramp narrows the inhalation gap 213 to less than the height of the apex 208 above the shoulder 210. In this embodiment, a portion of the gap between the inlet and outlet ramps 224, 226 and the shoulder 210 of the compression element 204 is smaller than the height of the expanded inlet channel 125, but does not completely pinch the inlet channel 125, so that it can continue to receive pressure from the outlets 246a, b. In other embodiments, the inlet and outlet ramps 224, 226 can narrow the inhalation and outlet gaps 213, 215 to a distance greater than the height of the expanded inlet channel 125.

[0065] In this embodiment, the guide body 234 includes a web control guide 212 that is longitudinally positioned between the inhalation portion 235 and the outlet portion 237. The web control guide 212 extends in the thickness direction 113 from the sealer guide member 222. The sealer guide member 222 receives the web 100 and establishes a material path 115 in the seal zone 276. In this embodiment, the sealer guide member 222 is configured as a static ski. In other embodiments, the sealer guide member 222 and / or the web control guide 212 may be provided as a rotating or moving element such as a wheel or a belt. In other embodiments, the web control guide 212 can be disposed between the inhalation portion 235, the outlet portion 237, or both. In other embodiments, the web control guide 212 can be included in a sealer guide member 228 that is located on the opposite side of the seal zone 276 from the sealer guide member 222 and can be provided in a manner similar to the web control guide 212 included in the sealer guide member 222.

[0066] The web control guide 212 has a web control surface 220 spaced from the compression member 204 to define a web control gap 201. The web control guide 212 is positioned along the material path 115 such that the web control gap 201 restricts the material path 115 in the seal zone 276 and bends the web material 100 laterally along the path 115. In this embodiment, the web control gap 201 is wider than the overlapping plies 105, 107 of the web 100, and thus the inlet channel 125 remains slightly open with respect to the sealing zone 276. In other embodiments, the web control gap can be made small enough to close and completely crush the inlet channel 125 from the sealing zone 276.

[0067] In this embodiment, the web control gap 201 has a transverse gap portion 205 that extends between the shoulder 210 of the compression element 204 and the web control guide 212. The web control gap 201 has a radial gap portion 203 between the sealer guide member 222 and the radial wall 221 of the crown 208 of the compression element 204. Thus, the web control gap in this embodiment causes a lateral bend in the web material 100. In other embodiments, the web control gap 201 can be linear with respect to any of the lateral, longitudinal, or thickness directions of the material 100. In some embodiments, the web control gap 201 can curve with respect to one or more axes, or can have a tapered or undulating profile. For clarity, the transverse gap portion 205 and the radial gap portion 203 are named with respect to the structure of the sealing assembly 200. Both the transverse gap portion 205 and the radial gap portion 203 limit the thickness of the material path 115 in the lateral direction of the web material 100. The web control gap 201 is smaller than the expansion height of the inlet channel 125.

[0068] The web control gap 201 including the lateral gap portion 205 and the radial gap portion 203 can align and restrain the web material 100, prevent the flexible material 100 moving laterally towards the compression elements 206, and avoid excessive heating of the web 100 outside the seal zone 276. The web control gap 201, the lateral gap portion 205, and the radial gap portion 203 can apply tension to the web material 100, make it linear and flat, and be small enough to prevent such lateral movement of the web material 100. For example, the pressurized fluid in the inflatable chamber 120 tends to push the plies 105, 107 of the web material 100 towards the heat sealer 202, causing the material to bunch up near the heat sealer and potentially burn. Further, the compression elements 204 and 206 can stretch the web material 100 and draw it into the heat sealer 202. The radial gap portion 203 and the first lateral gap portion 205 are small enough to limit the fluid in the inflatable chamber 120 from reaching the seal zone 276. For example, when the web 100 moves through the director portions 264, 266, the inflatable chamber 120 is inflated with pressurized fluid from the nozzles 240 via the outlets 246a, b.

[0069] FIG. 9 shows the expanded web 100 engaged with the sealing zone 276. The inlet channel 125 is constrained by the radial and lateral gap portions 203 and 205. Chamber portions 130 are shown in fluid communication with each other via the in-chamber passage 140. The lateral seal 118 is shown as defining the longitudinal edges of the expandable chamber 120. The radial gap portion 203 and the lateral gap portion 205 limit the thickness of the material path 115 in the thickness direction 113. In this embodiment, the lateral gap portion 205 limits the first thickness of the material path 115 in the thickness direction 113 and aligns the thickness direction of the web material 100 with the respective axes of the compression elements 204 and 206. For example, in this embodiment, the lateral gap portion 205 aligns the web material 100 with an axis parallel to the axis of rotation of the backing wheel 214. Similarly, the lateral gap portion 205 aligns the web material 100 with an axis parallel to the axis of rotation of the rotating seal element 216. In this embodiment, the radial gap portion 203 constrains the thickness direction of the material path 115 and aligns the web material 100 with an axis perpendicular to the axis of rotation of the backing wheel 214 and / or the rotating seal element 216. Also, the radial gap portion 203 can align the web material 100 parallel to the transverse walls 207, 209 of the rotating seal element 216.

[0070] In some embodiments, the pressurized fluid tends to escape from the expandable chamber 120 towards a lower pressure, being back-pressured by the compression elements 204, 206 when the plies 105, 107 are sealed together. Such back-pressure can cause an increase in power consumption in the heating element 270 because of poor seal quality, seal porosity, weak or incomplete seals, and unnecessary cooling due to blowback. The radial and lateral gap portions 203, 205 limit the expansion of the inlet channel 125 after expansion to prevent or reduce back-pressure during the sealing process.

[0071] As shown in FIGS. 6 - 9, in a preferred embodiment, the web control gap 201, the radial gap portion 203, and the lateral gap portion 205 defined by the shoulder 210 and the web control surface 220 are from about 5 mils to 25 mils (one - thousandth of an inch). In some embodiments, the web control gap is between at least 2.5 mils and 50 mils, typically between 5 mils and 15 mils or 5 mils and 25 mils. In other embodiments, the radial and lateral gap portions 203, 205 can be less than 1 mil. In other embodiments, the radial and lateral gap portions 203, 205 can be as large as 60 mils or 100 mils. In some embodiments, the lateral gap portion 205 and / or the radial gap portion 203 can be selected based on the thickness, number of plies, or type of the web material 100 supplied to the inflation and sealing device 101. For example, if each of the plies 105, 107 is 1 mil thick, the web material 100 is about 2 mils thick. If it is desired for the lateral gap portion 205 to have a total clearance of 2 mils across the thickness of the web 100, the lateral gap portion 205 can be about 4 mils. Thus, the web control guide 212 does not compress the web 100, but prevents the lateral movement of the web 100 to the heat sealer 200. The radial and lateral gap portions 203, 205 can be the same as each other or different. Similarly, in embodiments having two or more web control guides, each web control guide can provide different radial and lateral gap portions 203, 205 as desired.

[0072] The first lateral gap portion 205 is generally smaller than the director gap 269 between the opposing surfaces 265, 267 of the director portions 264, 266. In the illustrated embodiment, the web control guide 212 is downstream of the director portions 264, 266. In other embodiments, the web control guide 212 is upstream of the director portions 264, 266.

[0073] In other embodiments, the web control guide 212 can be spaced by radial or lateral gaps 203, 205 from the compression element 206 instead of the compression element 204. In other embodiments, one or more web control guides can be placed along the material path 115 at other points where it is desired to align the web material 100, for example, or prevent blowback.

[0074] The web control guide 212 and the sealer guide members 222, 228 can be made of suitable materials such as aluminum, aluminum coated with hard anodizing, hardened tool steel, or an inset of aluminum or other materials. The web control guide 212 and the sealer guide members 222, 228 can be made of molded plastics such as carbon-filled nylon or PEEK. The web control guide 212 and the sealer guide members 222, 228 can be coated with a low-friction, high-temperature coating such as PTFE to reduce snagging, focusing, or gathering of the web material 100 in the radial and lateral gap portions 203, 205.

[0075] In the illustrated embodiment, the second sealer guide member 228 is disposed laterally from the sealer guide member 222 on the opposite side of the compression element 206. In the illustrated embodiment, the second sealer guide member 228 does not include the web control guide 212. The second sealer guide member 228 defines an inflation side gap 211 in relation to one of the shoulders 210. A portion 151 of the web material 100 (see, FIG. 1) is received in the inflation side gap 211. In other embodiments, the web control guide 212 may be disposed on the sealer guide member 228. In some embodiments, the web control guide 212 can be disposed on one or both of the sealer guide members 222, 228. In some embodiments, the web control guide 212 can be disposed above the web material 100 in addition to, or instead of, below the web material 100 as shown.

[0076] The sealer guide members 222, 228 are disposed along a portion of the backing element 214 in the vicinity of the seal element 216. In this embodiment, the sealer guide members 222, 228 are disposed along a portion of the circumference of the wheel 214 in the vicinity of the rotary seal element 216 as shown in FIGS. 6 - 9. In some embodiments, the web control guide has a longitudinal length that is a substantial portion of the length of one of the compression elements 204, 206. The sealer guide members 222, 228 have an arcuate shape that follows the circumference of the wheel 214 in some portions. As shown in FIGS. 7 - 9, the sealer guide members 222, 228, together with the crown 208 of the compression element 204, provide the web material 100 to the seal element 216 in a smooth and flat state without wrinkling the web material 100 and securely form a longitudinal seal 170 for confining the inflation gas within the inflatable chamber 120. In other embodiments, the sealer guide members 222, 228 follow the shape of the compression element 204.

[0077] As shown in FIGS. 4, 6, and 11, a downstream seal finisher, such as nip roller 218, defines a portion of material path 115 downstream of seal zone 276. The nip roller 218 is attached to a shaft 217 extending from a support structure 141. The nip roller 218 is coupled to the shoulder 210 of the compression member 204, stretches the material near the crown 208, and compresses and stretches the web material 100 therebetween after the web 100 contacts the heat sealer 202. When the web material 100 contacts the nip roller 218, the material can still be at least partially molten or softened from the heat sealer 202. Thus, the nip roller 218 can further strengthen the longitudinal seal 170 and smooth the web material 100. Also, the nip roller 218 can cool as the web material is compressed, strengthening the seal 170 and completing its formation. The nip roller 218 can have a profile suitable for operating in conjunction with the compression member 204.

[0078] The inflation and sealing device 101 includes a cutting assembly 250 for cutting the web material 100. The cutting assembly 250 includes a cutter 252 disposed to cut through the inflation channel 114 from the nozzle 240. The cutter 252 can include a stationary or rotating cutting element. The cutter 252 can typically be a sharp one that cuts by slicing, an abrasive one that cuts by abrasion, or other suitable cutting mechanism.

[0079] As shown in FIG. 13, in this embodiment, the cutter 252 is a blade having a cutting edge 253 sharp enough to cut when the web material 100 is drawn out beyond the cutting edge 253 along the material path 115. The cutting assembly 250 in this embodiment is arranged to cut the web 100 at a lateral position between the first longitudinal edge 110 and the inlet channel 125 of the inflatable chamber 120. However, in alternative embodiments, other positions may be adopted, such as the position regarding the inflation nozzle. The cutter 252 cuts the web material 100 to open the inflation channel 114 of the web material 100, enabling the web to come off the inflation nozzle 240. In various embodiments, the inflation channel 114 of the flexible structure 100 can be at the center or other positions of the web 100, and the configurations of the inflation mechanism, the sealing mechanism, and the cutting mechanism are changed accordingly.

[0080] The cutter 252 cuts the web material 100 at a cutting position 251 where the cutting edge 253 is adjacent to the outside of the nozzle 240. At the cutting position 251, the cutting edge 253 faces upstream and cuts the web material 100 when the web material 100 moves along the path 115 past the cutting position 251, so that the inflation channel 114 can come off the nozzle 240. In this embodiment, as shown in FIGS. 7-9 and FIG. 13, the cutter 252 projects into the inside of the nozzle 240 through a cutter receiving aperture 257 formed in the nozzle 240. As shown, the cutter receiving aperture 257 can be provided as a cutter receiving slot.

[0081] As shown in FIG. 9, in this embodiment, the cutting position 251 is a common station that takes the sealing assembly 200 in the lateral direction. The sealing zone 276 in this embodiment longitudinally overlaps with the longitudinal position of the cutting position 251. In other embodiments, the cutting position 251 is downstream of the sealing zone 276. In other embodiments, the cutting position 251 can be located slightly in front of the sealing zone 276, preferably close to the longitudinal starting point of the sealing position, in order to minimize the pressure loss from the inflatable chamber.

[0082] In this embodiment, a pressure maintenance outlet 246b is provided as an opening of the nozzle that longitudinally overlaps with the cutting position 251. Further, the pressure maintenance outlet 246b preferably longitudinally overlaps with the seal zone 276. In other embodiments, the longitudinal position of the pressure maintenance outlet 246b and the cutting position 251 are downstream of the sealing zone 276.

[0083] The cutting position 251 is at an angle with respect to the longitudinal axis 241 of the nozzle and the material path 115. The pressure maintenance outlet 246b is preferably directed laterally towards the inlet channel 125 of the web 100, and in this embodiment, laterally in the seal zone 276 to direct the flow direction 260 laterally, i.e., laterally with respect to the web 100 and the path 115. This directs the flow from the pressure maintenance outlet 246b directly towards the inlet channel 125, aids in maintaining the pressure within the inlet channel 125, and directly prevents fluid from flowing out of the pressurized inflatable chamber. This angular position can be varied, and in some embodiments, the flow direction 260 of the pressure maintenance outlet 246b can be at an angle of up to 45° from the lateral direction 111 of the web material 100, although other suitable angles are also possible. The circumferential width of the pressure maintenance outlet 246b in other embodiments can be such that a portion of the opening of the pressure maintenance outlet 246b is lateral within the inlet channel 125 and such that a portion is in another direction such as the thickness direction of the pass or web. In such embodiments, for example, a portion of the flow can be diverted laterally, but preferably, a portion of the flow is lateral and flows towards the inlet channel 125.

[0084] The cutting position 251 is preferably arranged at an angle by a cutting location displacement angle 259 from the fluid flow direction 260 outside the pressure maintenance outlet 246b. As shown in FIG. 9, in this embodiment, the cutting position displacement angle 259 is approximately 90°. In various embodiments, the cutting position displacement angle 259 is at least 30°, but preferably 80° or approximately 90° or more. In some embodiments, the cutting position is on the lateral side opposite the nozzle from the pressure maintenance outlet 246b. The pressure maintenance outlet 246b in the illustrated embodiment is a different opening from the cutter receiving opening, and the cutting position displacement angle 259 is sufficient to prevent or minimize the fluid from the pressure maintenance opening from directly escaping through the opening cut into the web by the cutter and to maximize the re-pressurizing effect of the fluid from the pressure maintenance opening in the inlet channel.

[0085] In some embodiments, the fluid pressure within the inflatable chamber 120, at completion, is above atmospheric pressure, typically in the range of 2 psig to 3 psig. In some embodiments, the pressure can range from less than 1 psig to 5 psig or 10 psig, or more. In other embodiments, the inflatable chamber 120 is filled to separate and expand the ply, but is not pressurized above atmospheric pressure. Other pressure ranges can be employed for other resulting inflatable protective packaging.

[0086] When the web material 100 passes through the cutting position 251 and the inflation channel 114 is cut, a leak is formed in the web material 100. The longitudinal overlap of the cutting position and the pressure maintenance outlet 246b, and the orientation of the lateral flow direction 260 with respect to the cutting position 251 (i.e., the cutting position displacement angle 259) have been found to contribute to increasing the pressurization of the inflatable chamber 120 because the flow from the pressure maintenance outlet 246b resists the pressure decay of the inflatable chamber 120 associated with the cutting of the inflation channel 114. The overlap of the cutting position 251, the seal zone 276, and the pressure maintenance outlet 246b resists pressure decay as the longitudinal seal 170 is formed and the inflatable chamber 120 is sealed. In some embodiments, the increase in pressure within the completed cushion 121 has been found to be significant on the order of 1 psig in tests when inflating the inflatable chamber to about 3 psig. In some embodiments, the increase in pressure has been found to be about 30% compared to positioning the cutting position 251 spaced from the nozzle outlet.

[0087] The cutting assembly 250 includes a carriage 254 that enables alignment and replacement of the cutter 252 as desired. The cutting assembly includes a positioning element 256 and a magnet 258 (hidden behind the cutter 252 in FIG. 13). The positioning element 256, the magnet 258, and the carriage 254 provide accurate positioning of the cutter 252. Such accurate alignment enables the use of hardened cutters 252 (e.g., made from hardened tool steel or tungsten carbide, etc.) that are more durable but brittle and thus more sensitive to breakage due to misalignment.

[0088] Any and all references specifically identified herein are hereby incorporated by reference in their entirety. The term "about" as used herein should generally be understood to refer to both the corresponding number and ranges of numbers. Further, all numerical ranges herein are to be understood to include each integer within the range.

[0089] Although several embodiments have been described herein, those skilled in the art will recognize that various modifications, alternative structures, and equivalents may be used. The various examples and embodiments may be employed individually or in combination to mix and adapt to form any iteration of alternatives. Further, to avoid unnecessarily obscuring the focus of the present disclosure, numerous well-known processes and elements have not been described. Accordingly, the above description should not be received as limiting the scope of the invention. Those skilled in the art will understand that the presently disclosed embodiments are taught by way of example and not limitation. Thus, the matters included in the above description or shown in the accompanying drawings should be construed as illustrative and not in a limiting sense. The following claims are intended to cover all general and specific features described herein, as well as all descriptions regarding the scope of methods and systems, and there may be room for interpretation as a matter of language.

Claims

1. A drive device configured to advance a web of flexible material along a longitudinally extending material path during operation; An inflation nozzle configured to direct fluid between overlapping plies of the web of flexible material in the material path and to inflate an expandable chamber defined between the plies with the fluid during operation; First and second opposing compression elements configured to compress the overlapping plies together in a seal zone along the material path during operation, and a heating element configured to supply heat to the seal zone, the first and second compression elements, and configured to jointly generate sufficient compression and heat in the compressed overlapping plies in the seal zone to heat-seal the overlapping plies together, thereby sealing the inflated expandable chamber and confining the fluid therein, a heat sealer including; A sealer guide member including a web control guide spaced laterally along the material path from the first compression element and configured to limit a first thickness of the material path measured perpendicular to the longitudinal and transverse directions of the material path, the limited first thickness dimension being small enough to prevent lateral movement of the web of flexible material toward the first compression element and to prevent overheating of the web of flexible material outside the seal zone; A web material director having a length in the longitudinal direction of the material path and arranged to have a length relative to the web control guide, and configured to limit a second thickness of the material path during operation, the second thickness being configured to be greater than the first thickness; A protective packaging forming device including.

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

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

4. The first compression element is wider laterally than the second compression element; The protective packaging forming device according to claim 1, wherein the web control guide is arranged opposite the first compression element and limits the first thickness between the web control guide and the first compression element.

5. A drive configured to advance a web of flexible material along a longitudinally extending material path during operation; An inflation nozzle configured to direct fluid between overlapping plies of the web of flexible material in the material path and to inflate an expandable chamber defined between the plies with the fluid during operation; A heat sealer including: first and second compression elements configured to compress the overlapping plies together in a seal zone along the material path during operation; and a heating element configured to supply heat to the seal zone, the first and second compression elements, and during operation, to jointly generate sufficient compression and heat in the compressed overlapping plies in the seal zone to heat seal the overlapping plies together, thereby sealing the inflated expandable chamber and containing the fluid therein; A web control guide spaced laterally from the first compression element and disposed along the material path and configured to limit a first thickness of the material path measured perpendicular to the longitudinal and transverse directions of the material path, the limited first thickness dimension being small enough to prevent lateral movement of the web of flexible material toward the first compression element and to prevent overheating of the web of flexible material outside the seal zone; The second compression element is a heated mass including a heated convex circumferential portion having a heated transverse wall extending therefrom; The protective packaging forming apparatus, wherein the limited first thickness dimension allows the web of flexible material to contact the convex circumferential portion and prevents contact with the heated transverse wall. **Claim 6** A drive configured to advance a web of flexible material along a longitudinally extending material path during operation; An inflation nozzle configured to direct fluid between overlapping plies of the web of flexible material in the material path and to inflate an expandable chamber defined between the plies with the fluid during operation; During operation, first and second opposing compression elements that are compressed against each other and configured to compress both of the plies that overlap in a seal zone along the material path, and during operation, configured to jointly generate sufficient compression and heat in the overlapping plies compressed in the seal zone to heat-seal the overlapping plies together, thereby sealing the expanded chamber and confining fluid therein, a heat sealer including a heating element configured to supply heat to the seal zone, the first and second compression elements. During operation, a web control guide disposed along the material path and laterally spaced from the first compression element and configured to limit a first thickness of the material path measured perpendicular to the longitudinal and transverse directions of the material path, the limited first thickness dimension being small enough to prevent lateral movement of the web of the flexible material toward the first compression element and prevent overheating of the web of the flexible material outside the seal zone. The second compression element is a heated wheel. The web control guide is a protective packaging forming device that curves along the curve of the heated wheel.

7. The protective packaging forming device according to claim 6, wherein the first compression element is operably coupled to a backing element.

8. The backing element is a backing wheel. The protective packaging forming device according to claim 7, wherein the backing wheel is arranged such that the first compression element contacts the second compression element and sandwiches the web of the flexible material therebetween.

9. The protective packaging forming device according to claim 8, wherein one of the backing wheel or the heated wheel is driven by a motor to pull the web of the flexible material through the protective packaging forming device.

10. The protective packaging forming device according to claim 1, wherein the transition between the web control guide and the sealer guide member is provided by a ramp.

11. The protective packaging forming device according to claim 1, wherein the first thickness is between 5 mils and 25 mils.

12. The protective packaging forming device according to claim 1, including a supply of web material attached to the protective packaging forming device, wherein the web material includes overlapping plies that define an expandable chamber therebetween. The ply defines a web thickness, A first thickness, a system greater than the web thickness.

13. The system according to claim 12, wherein the first thickness is selected such that the inflated expandable chamber expands the ply and contacts opposite limits of the limited first thickness dimension.

14. The protective packaging forming apparatus according to claim 1, wherein the web control guide is further configured to bend the web of the flexible material laterally along the material path during operation.

15. The limited first thickness dimension is small enough to prevent lateral movement of the flexible material towards the first compression element to avoid overheating of the web outside the seal zone, the protective packaging forming apparatus according to claim 1.

16. A drive configured to advance a web of flexible material along a longitudinally extending material path during operation; An inflation nozzle configured to direct fluid between overlapping plies of the web of flexible material in the material path during operation and to inflate an expandable chamber defined between the plies with the fluid; First and second opposing compression elements configured to compress together the overlapping plies in a seal zone along the material path during operation, and during operation, to jointly generate sufficient compression and heat in the overlapping plies compressed in the seal zone to heat-seal the overlapping plies together, thereby sealing the inflated expandable chamber and containing the fluid therein, and a heat supply configured to supply heat to the seal zone, the first and second compression elements. A heat sealer including a heating element; A web control guide disposed along the material path and laterally spaced from the first compression element and configured to limit a first thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path, the limited first thickness dimension preventing lateral movement of the web of the flexible material towards the first compression element and preventing overheating of the web of the flexible material outside the seal zone. Small enough to include, The web control guide includes a web control surface spaced from the first compression element to define a web control gap. The web control gap is a protective packaging forming device having the limited first thickness dimension. **Claim 17** The protective packaging forming device according to claim 16, wherein the web control gap has a radial gap portion and a first lateral gap portion. **Claim 18** The protective packaging forming device according to claim 17, wherein the radial gap portion and the first lateral gap portion are small enough to restrict access of fluid in the expandable chamber to a seal zone. **Claim 19** Further comprising a sealer guide member, wherein the web control guide extends in the first thickness direction from the sealer guide member, the first compression element has a shoulder and a top portion including a radial wall, the first lateral gap portion is defined by the web control guide and the shoulder of the first compression element, The protective packaging forming device according to claim 17, wherein the radial gap portion is defined by the sealer guide member and the radial wall of the top portion. **Claim 20** Further comprising a backing wheel, wherein the first compression element is disposed on the backing wheel, the first lateral gap portion is configured to align the web of the flexible material with an axis parallel to the axis of rotation of the backing wheel and an axis parallel to the axis of rotation of the second compression element during operation, The protective packaging forming device according to claim 17, wherein the radial gap portion is configured to align the web of the flexible material with an axis perpendicular to the axis of rotation of the backing wheel and / or the second compression element during operation, and to align the web of the flexible material parallel to the transverse wall of the second compression element. **Claim 21** The protective packaging forming device according to claim 17, wherein the radial gap portion and the first lateral gap portion are further configured to limit expansion of an inlet channel to the expanded expandable chamber after expansion of the expandable chamber during operation, to prevent or reduce back pressure during sealing of the expandable chamber. **Claim 22** Providing a drive device, using the drive device to advance a web of flexible material along a longitudinally extending material path, providing an inflation nozzle, using the inflation nozzle to direct fluid between overlapping plies of the web of flexible material in the material path and to inflate an expandable chamber defined between the plies with the fluid. Provide a heat sealer that includes first and second compression elements that are compressed against each other and a heating element, Using the heat sealer, Compress both of the plies that overlap in a seal zone along the material path, Supply heat to the seal zone, Generate sufficient compression and heat in the overlapping plies compressed in the seal zone to heat-seal the overlapping plies together, thereby sealing the expandable chamber that has expanded and confining fluid therein, Provide a web control guide that includes a web control surface spaced from the first compression element to define a web control gap, the web control surface being disposed laterally spaced from the first compression element along the material path, Using the web control surface of the web control guide to limit the thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path, the web control gap having a limited first thickness dimension, the limited first thickness dimension being small enough to prevent lateral movement of the web of the flexible material toward the first compression element and prevent overheating of the web of the flexible material outside the seal zone, a method for forming a protective packaging forming device.

23. A drive device configured to advance a web of flexible material along a longitudinally extending material path during operation, An inflation assembly configured to direct fluid between overlapping plies of the web of flexible material in the material path and inflate an expandable chamber defined between the plies with the fluid during operation, A heat sealer, A web control guide, and includes, The inflation assembly is, A web material director including a first director portion configured to contact a first surface of the web of the flexible material during operation and a second director portion configured to contact a second surface of the web of the flexible material during operation, An inflation nozzle disposed between the first and second director portions and configured to be received in an inflation channel formed between the overlapping plies during operation and flow fluid from there into the inflation channel to inflate the expandable chamber, and includes, The heat sealer is, First and second opposing compression elements that are compressed against each other and that, during operation, compress the plies overlapping in a seal zone along the material path together, A heating element configured to supply heat to the seal zone during operation, wherein the first and second compression elements and the heating element are arranged and configured to jointly generate sufficient compression and heat in the plies overlapping in the seal zone during operation to heat-seal the overlapping plies together, thereby sealing the inflated chamber and confining the fluid therein, A web control guide arranged along the material path at a lateral spacing from the first compression element and configured to limit a first thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path during operation, the limited first thickness dimension being small enough to prevent lateral movement of the web of flexible material towards the first compression element and prevent overheating of the web of flexible material outside the seal zone, A protective packaging forming device in which the first and second director portions contact the web of flexible material upstream of the seal zone along the material path during operation, couple to the inflated portion of the chamber, and extend in the lateral direction of the web of flexible material to keep the transverse axis of the web of flexible material oriented along the axis of the seal element and the axis of the opposing first and second compression elements that seal the overlapping plies together.

24. The protective packaging forming device according to claim 23, wherein the first and second director portions are configured to orient an inlet of the inflation channel towards an outlet of the inflation nozzle.

25. The first and second director portions each comprise a leading ramp surface, The leading ramp surface is, Inclined with respect to each other, The protective packaging forming device according to claim 23, having a tapered shape in the longitudinal direction such that a distance between the leading ramp surfaces gradually narrows as the web of flexible material passes through the first and second director portions in the longitudinal direction during operation.

26. The first and second director portions each comprise a lateral ramp surface, The lateral ramp surface is, Each is inclined and has a transverse tapered shape such that the director gap gradually narrows or widens with respect to the transverse portion of the web of the flexible material, the protective packaging forming apparatus according to claim 23.

27. The transverse ramp surface forms a longitudinal trough configured to receive a portion of the web of the flexible material during operation, the protective packaging forming apparatus according to claim 26.

28. The first and second director portions are configured such that during operation, when the web of the flexible material is inflated by the inflation nozzle, the overlapping plies press against the respective opposing surfaces of the first and second director portions, The opposing surfaces, respective leading ramp surfaces, and / or respective transverse ramp surfaces are configured to impart a reaction force to the inflated portion of the web of the flexible material during operation to orient the transverse axis of the web of the flexible material to the axis of the seal element and the axes of the opposing first and second compression elements, the protective packaging forming apparatus of claim 25.

29. The opposing surfaces of the first and second director portions and the transverse ramp surface are configured such that an internal seal of the web of the flexible material is formed at the transverse position of the longitudinal trough, the protective packaging forming apparatus according to claim 28.

30. The first and second director portions each have opposing surfaces spaced apart from each other by a first distance to limit the thickness of the material path, the protective packaging forming apparatus according to claim 23.

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

32. The first distance is selected based on the transverse width of the inflation channel of the web of the flexible material between the longitudinal end and the internal seal, the protective packaging forming apparatus according to claim 30.

33. A drive device configured to advance a web of flexible material along a longitudinally extending material path during operation, the flexible material including an inflation channel, An inflation nozzle received within the inflation channel, which during operation directs fluid between overlapping plies of the web of flexible material in the material path and is configured to inflate with fluid an inflatable chamber defined between the plies, the inflation nozzle including a pressure-maintaining outlet; A sealer configured to seal together the overlapping plies in a seal zone during operation; A cutter adjacent to the inflation nozzle at a cutting position and configured to cut the inflation channel during operation, the pressure-maintaining outlet longitudinally overlapping the cutting position; A protective packaging forming apparatus, wherein the pressure-maintaining outlet faces in an outlet direction and the cutting position is disposed at least 30 degrees away from the outlet direction with respect to the longitudinal axis of the inflation nozzle.

34. The protective packaging forming apparatus according to claim 33, wherein the cutting position overlaps the seal zone or is downstream of the seal zone.

35. The protective packaging forming apparatus according to claim 33, wherein the cutting position overlaps the seal zone.

36. The protective packaging forming apparatus according to claim 35, wherein the overlap of the pressure-maintaining outlet, the cutting position, and the seal zone together resists pressure decay within the inflatable chamber when the inflatable chamber is sealed.

37. The protective packaging forming apparatus according to claim 33, wherein the cutter is configured to slit open the inflation channel during operation such that the inflation channel can be detached from the inflation nozzle.

38. The protective packaging forming apparatus according to claim 33, wherein the cutter is configured to project into the interior of the inflation nozzle through a cutter receiving opening formed in the inflation nozzle.

39. The protective packaging forming apparatus according to claim 33, wherein the cutter is positioned adjacent to the outside of the inflation nozzle and has a cutting edge facing upstream with respect to the material path.

40. The protective packaging forming apparatus according to claim 33, wherein the cutter is positioned to cut the web of flexible material at a lateral position between a first longitudinal end of the web of flexible material and the inflation channel during operation.

41. The protective packaging forming apparatus according to claim 33, wherein the pressure-maintaining outlet is configured to direct the fluid in a lateral direction of the web of flexible material during operation.

42. The protective packaging forming device according to claim 33, wherein the pressure maintaining outlet is configured to direct the fluid at an angle of from about 0 degrees to about 45 degrees with respect to the lateral direction of the web of the flexible material during operation.

43. Provide a drive device, Using the drive device, advance a web of flexible material along a longitudinally extending material path, the flexible material including an inflation channel, Provide an inflation nozzle received within the inflation channel, the nozzle including a pressure maintaining outlet, Using the inflation nozzle, direct fluid between overlapping plies of the flexible material within the material path and inflate an inflatable chamber defined between the plies with the fluid, Provide a sealer, Using the sealer, seal overlapping plies together in a seal zone, Provide a cutter adjacent to the nozzle at a cutting position, A method for forming a protective packaging forming device, using the cutter to cut the inflation channel such that the pressure maintaining outlet longitudinally overlaps the cutting position.

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