Method for manufacturing an expandable wall, method for manufacturing an expandable wall, method for manufacturing a web, method for manufacturing an expandable wall web, and apparatus for manufacturing an expandable wall web

Abstract

A method for manufacturing an intumescent wall is provided. The method includes applying a matrix to a first ply and applying an expansion element to a surface of the matrix. A second ply is placed over the first ply, enclosing the matrix and expansion element therebetween. The applied expansion element provides an intumescent material entrapped in the applied matrix and configured to expand upon activation and solidify in the expanded state.

Description

Technical Field

[0001] The present disclosure generally relates to the packaging of shipped items. More specifically, the present disclosure relates to systems and methods for manufacturing expandable walls for use in packaging to provide cushioning to packaged articles.

Background Art

[0002] Conventional low-density protective packaging is manufactured in a standard bulky low-density configuration. These bulky low-density configurations may include, for example, pre-formed and inflated fluid chambers (such as bubble wrap), pre-inflated foams, insertion of pads, etc. These bulky low-density configurations provide support for the packaging during shipping. However, they need to be shipped to the packaging and shipping locations before being used in the packaging.

[0003] Protective wraps using expandable adhesives are disclosed, for example, in U.S. Patent Application 2019 / 0062028. Further, containers having thermally insulating expandable insulation are described, for example, in U.S. Patent 10,183,458).

[0004] Conventional protective packaging is manufactured in a bulky low-density configuration already, so it needs to be transported as such. This increases the shipping cost of the packaging material to the packaging and shipping locations even before it is used in the packaging, as the total amount of the packaging material increases, and reduces the amount of products that can be stored at these locations until they need to be used.

[0005] For at least these reasons, there is a need for systems and methods for manufacturing packaging materials in a low-volume, high-density configuration that can be expanded later.

Summary of the Invention

Problems to be Solved by the Invention

[0006] Traditional and more recent protective packaging is already manufactured in a bulky, low-density configuration and therefore needs to be transported in that manner. This increases the total volume of packaging material, even before it is used for packaging, thus increasing the cost of shipping packaging material to packaging and shipping locations, and reducing the amount of product that can be stored at these locations until it needs to be used.

[0007] For these reasons at least, there is a need for systems and methods to manufacture packaging materials in a low-volume, high-density configuration that can be expanded later. [Means for solving the problem]

[0008] Various embodiments of this disclosure provide a method for manufacturing an expansion wall. The method may include coating a matrix onto a first ply and coating an expansion element onto the surface of the matrix. In some embodiments, the expansion element is coated onto the coated matrix. In some embodiments, a second ply is placed over the first ply, enclosing the matrix and expansion element between them. In some embodiments, the second ply is placed over to form an expansion wall. In some embodiments, the coated expansion element provides an expansion material configured to be incorporated into the coated matrix, expand upon activation, and solidify in an expanded state. When the expansion material expands, it provides a pad between the first ply and the second ply. In some embodiments, the expansion element is selected so that the matrix and expansion material expand upon activation of the expansion element, and the matrix is ​​selected so that the expansion element solidifies upon activation to provide solidification of the expansion material.

[0009] In various embodiments, the first and second plies are compressed together to force the expansion element into the matrix. When activated, the expansion element can expand the matrix, increasing the spacing between the first and second plies.

[0010] In various embodiments, the expansion element includes fine particles that adhere to the surface of the matrix during application. In some embodiments, fine particles that do not adhere to the matrix during application can be recovered by a vacuum device strong enough to suck up the particles without damaging the first ply or the matrix having the expansion element on its surface. In some embodiments, the recovered particles can be reapplied to the surface of an additional matrix to provide an additional matrix on the first ply having the recovered particles on its surface, and the ply can be compressed with the additional adhesive and the reapplied particles.

[0011] In various embodiments, the application of the expansion element involves a coating apparatus that sprays the expansion element in a randomly dispersed manner in the general direction of the first ply and matrix. In some embodiments, the expansion element is applied to the matrix before it is applied to the first ply. In some embodiments, the expansion element comprises a plurality of microspheres, each containing a material from which a gas is released when activated. In some embodiments, the matrix is ​​a fluid. In some embodiments, the matrix is ​​a starch-based adhesive.

[0012] In various embodiments, activation of the expansion element involves forming an expansion wall. In some embodiments, activation of the expansion element includes irradiation with radiation. In some embodiments, activation of the expansion element is caused by a chemical reaction.

[0013] In some embodiments, the first and second prisms include paper. In some embodiments, the first and second prisms are formed when a single web of sheet material is folded along a fold line such that the first and second prisms are on opposite sides of the fold line. In some embodiments, the first and second prisms are formed from separate sheets of a single web of sheet material. In some embodiments, the first and second prisms include longitudinal edges that align when the second ply is placed over the first ply.

[0014] In various embodiments, the method includes forming the expansion wall into a dense supply configuration. In some embodiments, forming the expansion wall causes the applied expansion material to be incorporated. In some embodiments, forming the expansion wall includes making the expansion wall rolled or fan-folded in order to provide a supply of the expansion wall.

[0015] In various embodiments, the method includes forming an embrittlement region that extends transversely across one or both of the first and second plies and is configured to facilitate the separation of portions of the plies from each other.

[0016] In various embodiments, the method includes folding the expansion wall along a fold line to position the first side of the expansion wall relative to the second side of the expansion wall, and sealing the first side of the expansion wall to the second side of the expansion wall to define an internal cavity configured to receive an article to be packaged between the first and second sides. In some embodiments, the expansion elements of the folded expansion wall are activated to form a padded container including the internal cavity.

[0017] In various embodiments, coating the matrix includes dispensing the matrix, and coating the expansion element includes dispensing the expansion element to coat the surface of the dispensed matrix as the dispensed matrix is ​​moving toward the first ply, so that the matrix is ​​coated toward the first ply with the expansion element on its surface. In some embodiments, the matrix is ​​dispensed by ejecting the matrix in a trajectory toward the first ply, and the expansion element is coated onto the dispensed matrix as the matrix is ​​moving along the trajectory.

[0018] Various embodiments of this disclosure provide further methods for manufacturing an expansion wall. These methods may include coating a matrix onto a first ply, coating expansion elements onto the surface of the coated matrix, and covering the first ply with a second ply so as to confine the matrix and expansion elements between them. The matrix is ​​selected such that, after expansion, the expanded matrix solidifies to provide a pad between the first and second plies. In some embodiments, an apparatus is used to move a first ply having a coated matrix so that the expansion elements are coated onto the coated matrix on the moving ply. In some embodiments, the coated expansion elements are incorporated into the coated matrix. In some embodiments, the expansion elements are activated to form an expansion wall web.

[0019] According to various embodiments of the present disclosure, an apparatus for manufacturing an expanded wall web is provided. The apparatus includes a matrix applicator for applying a matrix to a first ply; an expanded element applicator for applying expanded elements to the surface of the matrix; and an intake device for incorporating the applied expanded elements into the matrix so that the matrix expands upon activation of the expanded elements and solidifies in an expanded state. In some embodiments, the apparatus includes an intake device for incorporating the applied expanded elements into the matrix so as to activate the expanded elements, expand the matrix, and solidify in an expanded state. In some embodiments, the apparatus includes an expanded activation device for activating the expanded elements and causing the expanded material to expand.

[0020] Various embodiments of this disclosure provide an expansion wall assembly. The expansion wall assembly includes a first ply and an expansion material applied to the first ply. The expansion material may include expansion elements applied to the matrix and the surface of the matrix such that there are substantially no expansion elements inside the matrix. The expansion elements expand the expansion material and solidify it in an expanded state. In some embodiments, a second ply is positioned above the first ply to confine the expansion members between them.

[0021] The aforementioned and other features of this disclosure will become more fully apparent from the following description and the attached claims, taken in conjunction with the attached drawings. While it is understood that these drawings illustrate only a few examples relating to this disclosure and are therefore not intended to limit its scope, the disclosure will be described more specifically and in detail through reference to the attached drawings, as follows: [Brief explanation of the drawing]

[0022] [Figure 1] This is a side view of the apparatus for manufacturing an expanded wall according to the embodiment. [Figure 2] This is a side view of the apparatus for manufacturing an expanded wall according to the embodiment. [Figure 3] This is a side view of the apparatus for manufacturing an expanded wall according to the embodiment. [Figure 4] It is a side view of an apparatus for manufacturing an expansion wall according to an embodiment. [Figure 5] For example, it is a side view of an apparatus for manufacturing an inflated package using an expansion wall manufactured according to the embodiments of FIGS. 1 to 4. [Figure 6] For example, it is a side view of an apparatus for manufacturing an inflated package using an expansion wall manufactured according to the embodiments of FIGS. 1 to 4. [Figure 7A] It is a side view of a system for converting a stock material into a supply chain of separable packaging containers configured as shown in, for example, FIG. 9B. [Figure 7B] It is a top view of a system for converting a stock material into a supply chain of separable packaging containers configured as shown in, for example, FIG. 9B. [Figure 8] It is a top perspective view of one embodiment of a ply used to form an expansion wall. [Figure 9A] It is a top view of an example of an expansion wall. [Figure 9B] It is a longitudinal sectional view of an expansion wall folded and sealed to form a web of connected packaging packages according to one embodiment, for example, the expansion wall of FIG. 9A. [Figure 10A] It is a top broken view of another embodiment of an expansion wall. [Figure 10B] It is a bottom perspective view of the web of FIG. 10A folded and adhered to form a web of connected packaging containers. [Figure 10C] It is a longitudinal sectional view of the web of FIG. 10B. [Figure 11A] It is a top view of an expansion wall used to form a packaging container according to one embodiment. [Figure 11B] It is a longitudinal sectional view of a packaging container formed from the expansion wall of FIG. 11A. [Figure 12] For example, it is a perspective view of a completed roll-shaped supply web of separable packaging containers configured as shown in FIG. 11B. [Figure 13]For example, Figure 11B shows a perspective view of a completed supply web of a separable packaging container configured in a fanfold configuration. [Figure 14A] For example, Figure 13 is a perspective view of an inflation and bagging apparatus according to one embodiment, using the supply web. [Figure 14B] For example, Figure 13 is a side cross-sectional view of an inflation and bagging apparatus according to one embodiment, using the supply web. [Figure 15A] This is a rear view of an inflation and bagging apparatus according to one embodiment. [Figure 15B] This is a front view of an inflation and bagging apparatus according to one embodiment. [Modes for carrying out the invention]

[0023] The following detailed description refers to the accompanying drawings, which constitute part of this specification. In the drawings, similar symbols typically identify similar components unless the context otherwise indicates. The detailed description, drawings, and exemplary embodiments described in the claims are not intended to limit. Other examples may be available, and other modifications may be made without departing from the spirit or scope of the subject matter presented herein. It will be readily apparent that aspects of this disclosure may be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, as generally described herein and shown in the figures, all of which will be readily apparent herein.

[0024] This disclosure relates to systems and methods for manufacturing packaging materials. In some embodiments, the packaging material may include pads and sheets having a single wall. In some embodiments, the packaging material includes a packaging unit configured to cushion one or more articles during shipment. The packaging unit may include, for example, a pad and a packaging container. The packaging container includes multiple walls surrounding an internal cavity for storing one or more products. In some embodiments, the packaging container includes bags and envelopes, such as mailers, which may be filled with articles to be shipped at a later date after they have been manufactured. An example in which this material may be used is found in U.S. Patent Application No. 16 / 599,679, the bagger, the entirety of which is incorporated in this application.

[0025] Some embodiments of the present disclosure include an expandable wall. Some expandable walls include expandable walls that are in an unexpanded configuration and can be expanded at a later time. Some expandable walls include expanded walls, which are already in an expanded configuration. An expandable wall may include one or more expandable materials configured to expand the expandable wall. Some expandable materials include expandable materials configured to expand by the application of one or more expansion conditions, such as heat or a chemical reaction or other suitable means.

[0026] [Conversion device]

[0027] Referring here to Figure 1, an apparatus 30 is shown for converting sheet materials 32, 34 into a supply of an expandable expandable wall web or an expandable wall 38 for supplying an expandable wall 36. The expandable wall 38 includes a first ply 32 and a second ply 34. The first ply 32 is supplied from the stock support 40 in direction 42, and the second ply 34 is supplied from the stock support 44 in direction 464, so that the second ply 34 covers the first ply 32. The expandable material 48 is applied to the first ply 32 by the expandable material applicator 50 to generate the expandable wall assembly before adding the second ply 34. The expandable material 48 encases the matrix 52, which is applied to the first ply 32 as droplets 54 that are ejected or discharged by the matrix applicator 56, and the expandable elements 58, which are applied by the expandable element depositor 60. The expandable material applicator 50 includes the matrix applicator 56 and the expandable element depositor 60. The matrix 52 may be applied in other patterns, such as lines or shapes, as will be described in more detail later. In some embodiments, the matrix 52 and the expansion element 58 are not pre-mixed.

[0028] In some embodiments, the matrix 52 and expansion element 58 are applied to the first ply 32 while the first ply 32 is moving through the apparatus 30. In some embodiments, the matrix 52 and expansion element 58 are applied to the first ply 32 while the first ply 32 is stationary. In one embodiment, the expansion elements 58 are deposited on the surfaces of the first ply 32 and matrix 52 in a random, non-focused manner after the matrix 52 has been deposited on the first ply 32, as illustrated in Figure 1. In this case, the expansion elements 58 adhere to at least a portion of the surface of the matrix 52, and there are substantially no expansion elements 58 inside the matrix 52. The expansion elements 58 that did not deposit on the surface of the matrix 52 can then be recovered or recaptured back into the expansion element depositor 60 by a recapture device 62, such as a vacuum, and reattached to the first ply 32 and matrix 52. The recapture device 62 is configured to be strong enough to suck up the free expansion elements 58 without damaging the first ply 32 or matrix 52 to which the expansion elements 58 are already adhered.

[0029] In other embodiments, as shown in Figures 2 and 3, the apparatus 30 may include an expansion element director 64, such as an air knife or blower. The expansion element director 64 may be used to disperse the flow of expansion elements 58 toward the first ply 32 and toward the matrix 52 already deposited on the first ply 32, for example, as in Figure 2. In another embodiment, as shown in Figure 3, the expansion element director 64 may be used to direct the flow of expansion elements 58 directly toward the surface of the matrix 52 before it is deposited on the first ply 32, so that the matrix 52 is discharged in a trajectory toward the first ply 32, the expansion elements 58 combine with the air flow of the air knife, and the air flow of the air knife is directed toward the trajectory of the matrix 52 before it reaches the first ply 32. In a further embodiment, the expansion elements 58 are applied to the first ply 32 before the matrix 52 is applied, so that the expansion elements 58 are positioned between the first ply 32 and the matrix 52.

[0030] In some embodiments, the expansion element depositor 60 and the expansion element director 64 may be combined so that the expansion elements 58 are directed as they exit the depositor 60. In other embodiments, the expansion element depositor 60 and the expansion element director 64 may be separate so that the expansion elements 58 are directed after they exit the depositor but before they are deposited on the matrix 52 or the first ply 32.

[0031] In some embodiments, after the expansion material 48 is applied to the first ply 32, the second ply 34 is placed over the first ply 32 to form an expandable wall 66 containing a matrix 52 and expansion elements 58 trapped between the first and second prisms 32, 34. The matrix 52 and expansion elements 58 constituting the expansion material 48 are joined in situ on or between the prisms 32, 34 by entrainment, mixing, or other suitable method. In some embodiments, the expansion elements 58 are mixed into the matrix 52 by an entrainment device 68. The entrainment device 68 may include a set of rollers 70, 72, 74, 76 that apply pressure to either side of the expansion wall 38, as shown in Figures 1 to 3, or a single roller 78 that pulls the expansion wall 38 in direction 80, causing tensile pressure on the wall, as shown in Figure 4. In some embodiments, entrainment occurs when the expansion wall 38 is wound onto a supply roll configuration 84. The pressure applied to the expansion wall 38 by rollers 70, 72, 74, 76, 78, or the feed roll 84 compresses the first and second plies 32, 34 together, flattening and compressing the matrix 52 and causing the expansion element 58 to be pressed into the surface of the matrix 52 to form a high-density expandable wall 66. In other embodiments, different take-in devices may be used to introduce the expansion element 58 from the surface of the matrix 52. Other take-in devices 68 or methods of combining the matrix 52 with the expansion element 58 may include, for example, vibration, agitation, or heating of the expansion element 58. In some embodiments, the expansion element 58 is not incorporated into the matrix 52 but remains on the surface of the matrix 52. In some embodiments, the second ply 34 is not placed over the expansion element 58 before its incorporation into the matrix 52.

[0032] In some embodiments, as shown in Figures 1 to 3, the expansion element 58 within the expandable wall 66 is activated by the expansion device 82 to cause the expansion material 48 to expand, thereby foaming and expanding the matrix 52 and the expandable wall. 36The expansion device 82 can provide thermal and / or mechanical and / or chemical activation, and / or other suitable initiation properties for activating the expansion element 58. For example, the expansion device 82 can provide one or more of heat, pressure, agitation, chemical reaction, and / or other suitable expansion activators.

[0033] In other embodiments, as shown in Figure 4, the inflatable walls 66 are not inflated and are assembled into a dense, uninflated, high-density supply configuration to form a web stock of packaging material. According to some embodiments, the uninflated, high-density supply configuration can be wound into a supply roll configuration, as illustrated exemplary in Figure 4. The roll configuration 84 can be a cored roll configuration or a coreless roll configuration. Another preferred high-density supply configuration is obtained by folding the inflatable walls 66 into a fanfold stack configuration having opposing folds 86, such as a fanfold (e.g., accordion) configuration 85 (as illustrated exemplary in Figure 7), and / or other suitable configurations. Another preferred high-density supply configuration is a series of two or more stacked inflatable walls 66.

[0034] As shown in Figures 5 and 6, the expansion wall can be further processed into packaging 88 by the packaging forming apparatus 90. In some embodiments, the packaging is as seen in Figure 5, the expansion wall 36 It can be made from an inflatable wall 66 to produce inflated packaging such as a padded container or padded mailer 88. In some embodiments, the packaging can be made from an inflatable wall 66, as shown in Figure 6. When the packaging is made from an inflatable wall 66, the packaging has a high-density structure 92 and can be efficiently stored or transported before being inflated using an inflation device 82 to form inflated packaging such as a padded mailer 88.

[0035] Next, referring to Figures 7A and 7B, a system 100 for converting stock material into a supply chain for packaging containers is shown. The expansion wall includes a first ply 32 and a second ply 34. The first ply 32 is supplied in direction 42 and the second ply 34 in direction 46, and the first ply 32 is joined to the second ply 34. The expansion material 48 is applied to the first ply 32 using an expansion material applicator 50 (which may include the matrix applicator 56 and expansion element depositor 60 described above) that dispenses the expansion material 48, and one or more seal materials 102 are applied to the first ply 32 using a seal material applicator 104. After the expansion material 48 and seal materials 102 have been applied, the first ply 32 and the second ply 34 are joined. The joining may include applying pressure using a pressure applicator 106 configured to apply pressure to the first ply 32 and the second ply 34.

[0036] After the first ply 32 and the second ply 34 are joined, one or more external sealing materials are applied to the outside of the expansion wall 38, and one or more external seals 108, 110 (Figure 9 A is formed (as shown in more detail in A). One or more longitudinal seals 108 are applied to the outer longitudinal end 112 of the expansion wall 38 using a longitudinal seal applicator 114, and one or more transverse seals 110, 116 are applied between one or more longitudinal seals 108 using a transverse seal applicator 118. The expansion wall 38 is then supplied through a folding device 122 that folds the expansion wall 38 in direction 120.

[0037] The folding device 122 includes a folding mechanism 124 (e.g., a folding bar 124). A tensioning mechanism 126 (e.g., wheels) applies tension to the expansion wall 38, causing the folding bar 124 to fold the expansion wall 38 along the shape of the folding bar 124. The folding mechanism 124 can be a V-shaped folding bar or other suitable folding shape. For example, in some alternative embodiments, the folding mechanism 124 includes multiple bends.

[0038] The expansion wall 38 is folded along the folding end 128. The folding device 122 includes a flattening mechanism 130 configured to flatten the expansion wall 38 once it has been folded by the folding mechanism 124. The flattening mechanism 130 is a flattening bar configured to apply pressure to the expansion wall 38 and flatten it. The expansion wall 38 is then sealed along one or more longitudinal seals 108 using a sealing device. The flattening mechanism function 130 can function as a sealing device. In other embodiments, the system 100 may alternatively incorporate a separate sealing device. The sealing device is configured to apply heat, pressure, and / or other suitable means to activate one or more longitudinal seals 108.

[0039] System 100 includes a cutting device 132. The cutting device 132 is configured to form one or more brittle regions 134 and openings 136 in the expansion wall 38. The one or more brittle regions 134 are configured to help separate the expansion wall 38 into one or more separate packaging elements (e.g., one or more packaging containers). The openings 136 are configured to allow access to each of the internal cavities 138 of one or more packaging containers 140. The openings 136 can be slits. In other embodiments, the openings 136 are configured to be torn rather than completely cut open by the cutting device 132. Note that the one or more brittle regions 134 and / or openings 136 can be formed before or after the compaction of the expansion wall 38. The cutting device 132 includes an upper compression roller 142 and a lower compression roller 144. The upper compression roller 142 includes a series of teeth 146 configured to puncture the expansion wall 38, forming a transversely embrittlement region 134 with respect to the longitudinal end of the folded expansion wall 38. The lower compression roller 146 may include a rigid surface, elastomer, or other suitable material. In some embodiments, the cutting device includes one or more blades, a heat cutter, and / or other suitable means for cutting one or more portions of the expansion wall 38.

[0040] The expansion wall 38 includes one or more embrittlement regions 134 extending laterally (e.g., substantially perpendicularly) with respect to the longitudinal direction at one or more of its longitudinal ends. In other embodiments, the embrittlement regions 134 are alternatively located at other locations along the lateral direction of the expansion wall 38. The embrittlement regions 134 can be provided by perforations, scoring, or other suitable techniques for embrittlement of the material at desired locations to facilitate the separation of individual envelope sections. The embrittlement regions 134 can be provided between each pair of adjacent packaging container forms 140, thereby separating the individual packaging container forms 140. The embrittlement regions 134 can be provided around the lateral seals 110, 116. The embrittlement regions 134 can penetrate both prisms 32, 34, or alternatively, penetrate one ply. The expansion wall 38 may include one or more slits configured to assist in the separation of adjacent packaging container forms 140.

[0041] To prevent the expansion material 48 from leaking from the packaging container forming body 140 (especially when the expansion material is expanded using a chemical reaction), the transverse seal 148 of the first ply 32 and the transverse seal 150 of the second ply 34 can be positioned to surround the areas before and after the embrittlement region 134. The expansion wall 38 may include one or more slits at its longitudinal end to aid in separation.

[0042] System 100 includes a consolidation device 152 configured to consolidate the expansion wall 38 into an unexpanded, high-density configuration, such as a roll configuration 84, a fanfold stack configuration 85, and / or other suitable configurations. The consolidation device 152 is configured to bend, wind, and / or otherwise change the shape of the expansion wall 38 into a consolidated, unexpanded, high-density configuration. In other embodiments, the consolidation device may also include an expansion device 82 so that the expansion wall 38 is formed into an expanded, low-density configuration.

[0043] It should be noted that the expansion agent 48 and / or the sealing material 102 may be applied to the first ply 32 and / or the second ply 34. [Sheet material]

[0044] As described above, the web of the sheet material of the expansion wall 38 may include a first ply 32 and a second ply 34. The first ply 32 and the second ply 34 may be from separate sheets of the sheet material or from the same sheet of sheet material folded in half. One or more of the plies may include paper (e.g., corrugated cardboard, kraft paper, fiberboard, pulp paper, recycled paper, newspaper, and coated paper such as paper coated with wax, plastic, water-resistant material, and / or stain-resistant material), plastic, cellulose, foil, poly or synthetic material, biodegradable material, and / or other suitable material of appropriate thickness, weight, and dimensions. The plies may include recyclable material (e.g., recyclable paper). The expansion material 48 may be placed between the first ply 32 and the second ply 34. When placed, the expansion material 48 is in an unexpanded configuration.

[0045] Referring to Figure 8, the expansion wall 38 includes a first ply 32 and a second ply 34. In some embodiments, the first ply 32 includes one or more seals 154, 156 formed or coated thereon, which may include a sealing material. In some embodiments, one or more seals 154, 156 include one or more longitudinal seals 154 bonded along one or more longitudinal ends 158 of the first ply 32. One or more seals 154, 156 may additionally or alternatively include one or more transverse seals 156. In some embodiments, one or more transverse seals 156 extend to one or more of the longitudinal ends 158 of the first ply 32. In other embodiments, the transverse seals 156 extend across a portion of the first ply 32.

[0046] In some embodiments, the second ply 34 includes one or more seals 160, 162 containing sealing material. One or more seals 160, 162 may be configured to complement the seals 154, 156 of the first ply 32 and include one or more longitudinal seals 160 bonded along one or more longitudinal ends 164 of the second ply 34. One or more seals 160, 162 of the second ply 34 include one or more transverse seals 162. One or more transverse seals 162 extend to one or more of the longitudinal ends 164 of the second ply 34. In other embodiments, one or more transverse seals 162 extend across a portion of the second ply 34.

[0047] [Expanding agent]

[0048] As described above, the expanding material 48 comprises a matrix 52 and an expanding element 58, and can be expanded by an expansion device 82. Before the expansion of the expanding material 48, when the expanding material is still expandable (i.e., when the expanding material 48 is an expandable material), the matrix 52 can be a fluid such as a viscous gel or liquid. This allows it to be immediately applied onto the pies 32, 34. In other embodiments, the expanding material is provided as a solid and / or can go through a gel or fluid phase. For example, the solid matrix may be formed from fine particles that allow the expanding element to be incorporated into the matrix 52. The expansion device 82 can provide one or more of thermal and / or mechanical and / or chemical activation and / or other suitable initiation properties for activating the expanding element 58. For example, the expansion device 82 can provide one or more of heat, pressure, chemical reaction, and / or other suitable expansion initiators to activate the expanding element 58. In some embodiments, the expansion device 82 provides radiation such as microwave or high-frequency radiation that generates heat to activate the expanding element 58. The expansion element 58 may include a reactive component, a chemical catalyst, a foaming agent, a heating agent (which can heat the expansion material and / or raise the temperature of the expansion material), and / or other suitable expansion elements. In some embodiments, the expansion element 58 is kept separate from the matrix 52 by a barrier and for this purpose may be kept within another structure, such as a microparticle sphere shell. The expansion material 48, once expanded, provides a cushioning material configured to provide protection to one or more articles / products / etc. positioned against the first ply 32 or the second ply 34.

[0049] In some embodiments, when activated, the expansion element 58 can expand the expansion material 48 to a volume of about 3 to 200 times, about 20 to 150 times, or about 50 to 100 times. In some embodiments, when activated, the expansion element can expand the expansion material 48 to about 3 times, about 5 times, about 10 times, about 25 times, about 50 times, about 100 times, about 150 times, or about 200 times its original volume.

[0050] In some embodiments, the matrix 52 may include one or more polymers, including emulsion-based polymers. The one or more polymers may include vinyl acetate ethylene, polyvinyl acetate, polyvinyl alcohol, vinyl acetate copolymer, polyvinyl alcohol copolymer, dextrin-stabilized polyvinyl acetate, vinyl acetate copolymer, ethylene copolymer, vinyl acrylic, styrene acrylic, acrylic, styrene butyl rubber, polyurethane, polyolefin, biodegradable materials (e.g., cellulose and starch), and / or other suitable leavening agents.

[0051] In some embodiments, the matrix 52 may include a polyolefin-based adhesive or a polyolefin dispersion. The polyolefin dispersion may include polyethylene and / or polypropylene, a thermoplastic polymer, a polymer stabilizer containing at least one polar polymer, water, and / or other suitable polyolefin dispersions. Suitable polyolefin dispersions may include, for example, HYPOD® from Dow Chemical, or other suitable polyolefin dispersions.

[0052] In some embodiments, the matrix 52 is an aqueous adhesive. The aqueous adhesive may contain an aqueous polymer.

[0053] In some embodiments, the matrix 52 is based on starch in a natural or synthetic form. In some embodiments, the starch is in the form of ground microstarch powder. The diameter of the ground starch particles is between about 12 microns and about 20 microns. In some embodiments, the starch-based matrix contains one or more of water or other solvents, surfactants, polar binders, or other fillers. In some embodiments, for example, the matrix 52 contains up to 50% water. In some embodiments, for example, the matrix 52 consists of 30-40% starch.

[0054] Some embodiments include a barrier that separates the expansion element 58 from the matrix 52. A preferred type of barrier is a microsphere shell containing a blowing agent, a chemical catalyst, or a chemically reactive component as the expansion element. Other types of barriers can also be used as alternatives.

[0055] In some embodiments, the expansion element 58 comprises, for example, a plurality of microspheres that are expandable and / or burstable upon application of sufficient heat. The microspheres may include an outer shell and an inner core. A suitable outer shell may include, for example, a thermoplastic polymer such as polyacrylonitrile or PVC, and one or more of glass, rubber, starch, cellulose, ceramic, or other suitable materials. In some embodiments, the plurality of heat-expandable microspheres include a solid, liquid, or gaseous core comprising one or more hydrocarbons, water, or other suitable chemicals that can be activated to expand or burst the microsphere shells. In some embodiments, the microspheres may include a biodegradable material such as cellulose.

[0056] The expanding elements 58, such as microspheres, can be mixed with the matrix 52 before being applied to the first ply 32, or they can be placed on the matrix 52 after the matrix 52 has been applied to the first ply 32, for example, when the plies 32 and 34 are pressed together, by mixing or incorporating the microspheres into the matrix 52.

[0057] In some embodiments, the microspheres have an expansion temperature (Texp) at which they begin to expand, and a maximum temperature (Tmax), so that if the microspheres are heated beyond Tmax, they will burst. The Texp of the microspheres is not particularly limited, but is generally between about 60°C and about 250°C. The Tmax of the microspheres is generally between about 80°C and about 300°C. In some embodiments, Tmax is higher than 300°C. The microspheres are selected based on their maximum expansion temperature, depending on whether it is required that the microspheres burst. Tmax depends on several properties, including the physical properties of the microspheres, the physical properties of the matrix 52, and the physical properties of the ply on which the matrix 52 and the microspheres are deposited. Heat can be generated by suitable means, for example, high-frequency radiation. In some embodiments, high-frequency radiation is applied to the expander 48 at a frequency of about 10–45 MHz, or as appropriate for the composition of the microspheres and the material of the matrix 52. In other embodiments, other frequencies may be used. The selected heating parameters depend on the expander or material 48 used. Suitable microspheres are known in this field.

[0058] In some embodiments, the expansion element 58 contains a blowing agent such as a gas or a mixture of gases. Examples of suitable gases include air, carbon dioxide, nitrogen, argon, helium, methane, ethane, propane, isobutane, n-butane, neopentane, etc. In some embodiments, the gas or mixture of gases is added to the expansion material 48 by mechanical means. Examples of mechanical means include foamed, bubbled, or bubbled expansion material 48, which is created by injecting air or other gases into the expansion material to increase its volume. In other embodiments, the gas or mixture of gases may be enclosed in microspheres. When the microspheres are activated, they expand and may burst. The expansion of the microspheres causes the expansion of the expansion material 48. The bursting of the microspheres releases their contents, resulting in foaming and expansion of the expansion material 48. In some embodiments, the expansion wall 38 includes one or more vents or vent openings configured to allow gas (e.g., water vapor) produced by the application or expansion of the expansion material 48.

[0059] In some embodiments, the expansion element 58 includes one or more reactive components that trigger a chemical reaction to expand the matrix 52. The chemical reaction may include mixing two reactive components that react to generate foam. In some embodiments, a catalyst is used to increase the rate of the chemical reaction. In some embodiments, the two reactive components are separated by a barrier before mixing and expansion. The barrier separating the reactive components may be a microsphere shell, where the microsphere core consists of one or more reactive components, and the rupture of the microsphere releases its contents into one or more other reactive components, triggering a foam-forming reaction. Other barriers may also be used, such as walls, capsules, or other barrier-forming containers. An example of a reactive component that triggers expansion is mixing a liquid isocyanate with a multi-component liquid blend called a polyurethane resin. In this case, either the isocyanate or the polyurethane may be a combination of components, and the matrix 52 or expansion element 58 may have a barrier that separates them so that activation results in the removal or penetration of the barrier. When combined, these components release carbon dioxide and water vapor to produce polyurethane foam. Other reactive components that form foam when mixed may also be used.

[0060] In some embodiments, the expandable material 48 solidifies upon expansion, while in others, the expandable material 48 forms a gel or has another physical phase depending on the structure of the article. The expanded expandable material 48 is configured to form a protective pad and / or insulating area (e.g., thermal and / or noise insulating material). The method of solidifying the expandable material 48 is selected based on its physical properties and can be achieved by methods such as thermosetting, drying (e.g., air drying), curing, or other suitable processes such as known methods for transitioning a material from fluid to solid. For example, thermosetting plastics can solidify irreversibly by curing, while the solidification of thermoplastic plastics can be reversible.

[0061] In some embodiments, the expansion agent 48 is applied in a pattern. The pattern, distribution, and / or concentration of the expansion agent 48 are selected to achieve the desired pattern and / or insulating properties. In this embodiment, the expansion agent 48 is applied in a pattern of droplets 54. The droplets 54 can be dots, squares, circles, large and / or small shapes, or polygons. Other suitable patterns can be alternatively employed, for example, lines, arcs, circles, ellipses, squares, rectangles, polygons, or combinations thereof. The expansion agent 48 is applied over a portion of the surface of one or more plies 32, 34 of the expansion wall 38. Alternatively, the expansion agent 48 may be applied over all of the surfaces of one or more of the plies 32, 34. In this embodiment, the expansion agent is applied at a relatively uniform thickness. Other thicknesses, for example, variable thicknesses, can be alternatively employed. In some embodiments, lines of the expansion wall 38 can be left without the expansion agent 48 to form natural hinge lines or regions that bend more easily than other areas where the expansion agent 48 is expanded. In some embodiments, pressure is applied to the expansion material 48 during or after expansion, forming a hinge line or region that is more easily bent than other regions.

[0062] [Packaging material]

[0063] The packaging materials described herein may include sheets comprising one or more inflatable walls having a web of inflatable walls 38 and transverse seals 110, 116 defining individual packaging units 93. The packaging units may include pads having a single inflatable wall 38, or packaging containers 88, 92 having multiple inflatable walls 38. The packaging containers 88, 92 may include bags or mailers, which may be a high-density uninflated configuration 92, or a low-density inflated configuration 88, such as a padded mailer. The pads or packaging containers may be shipped to the user in a high-density uninflated configuration and later inflated by the user, or the pads or packaging containers may be shipped to the user in a low-density inflated configuration.

[0064] In some embodiments, after the expansion wall 38 is formed with expansion material 48 on the first and / or second prisms 32, 34, one or more external sealing materials may be applied to the outside of the expansion wall 38 to form one or more external seals 108, 110, 116 (as shown in Figure 9A). One or more longitudinal seals 108 are applied to the outer longitudinal end 112 of the expansion wall 38, and one or more transverse seals 110 are applied between the one or more longitudinal seals 108. The expansion wall 38 is then supplied in direction 120 (as shown in Figure 7A) through a folding device that folds the expansion wall 38. In this embodiment, the expansion wall 38 is folded along the folding end 166. In other embodiments, the expansion wall 38 alternatively has multiple folding ends 166.

[0065] The expansion wall 38 may include one or more outer longitudinal seals 108 and one or more transverse seals 110, 116. The transverse seals 110 form a bottom seal of one or more packaging containers 88, 92. In this embodiment, the transverse seals 116 are configured to seal the opening of the packaging containers 88, 92 after the product has been inserted into the internal cavity of the packaging containers 88, 92. According to this embodiment, the transverse seals 110, 116 are of different seal types. In this embodiment, one or more of the transverse seals 110, 116 are of a different seal type from one or more longitudinal seals 108. In other embodiments, one or more of the transverse seals 110, 116 are, alternatively, of the same seal type as one or more longitudinal seals 108. According to some embodiments, one or more longitudinal seals 108 can form a seal at a temperature different from the temperature required to form a seal using one or more transverse seals 110, 116 in some embodiments. This allows a seal activated at a certain temperature to be activated in a different time than one or more seals activated at other temperatures. In some embodiments, each of the seals 108, 110, and 116 can be a thermally activated seal.

[0066] The packaging containers 88, 92 may include one or more web or expansion wall 38 layers having surfaces including first and second regions, where corresponding first regions (e.g., regions where seals 108, 110 are located in Figure 9A) are overlapped and corresponding second regions (e.g., regions where seal 116 is located in Figure 9A) are overlapped, the overlapped first and second regions cooperatively enclose a cavity 138 defined between at least one expansion wall 38 layer. The expansion wall 38 may include a first sealing material located in the first region and configured to seal corresponding first regions of at least one expansion wall 38 layer together when a first condition is applied to the first sealing material. The expansion wall 38 may include a second sealing material located in the second region and configured to seal corresponding second regions of at least one expansion wall 38 layer together when a second condition is applied to the second sealing material. The second sealing material is configured such that the first condition applied to the second sealing material is insufficient to seal the second sealing material. In some embodiments, the first and second sealing materials are different materials. Corresponding first regions are sealed to each other by the first sealing material, and the second sealing material is unsealed, forming an opening to the internal cavity 138, the opening configured to receive an object into the internal cavity. In some embodiments, the second sealing material is configured to seal the opening. In some embodiments, corresponding first regions are sealed to each other, and corresponding second regions are sealed to each other. In some embodiments, at least one expansion wall 38 layer includes a long expansion wall 38 layer and a short expansion wall 38 layer, the second region of the long expansion wall 38 layer is located on the long expansion wall 38 layer in a direction facing the internal cavity 138, and the second region of the short expansion wall 38 layer is located on the short expansion wall 38 layer in a direction facing outward from the internal cavity 138.

[0067] In some embodiments, one or more longitudinal seals 108 and one or more transverse seals 110, 116 include a sealing material configured to establish a seal without the application of heat. For example, one or more longitudinal seals 108 and one or more transverse seals 110, 116 include a pressure-activated adhesive, a cold glue (e.g., a collagen-based adhesive, a polyvinyl acetate-based adhesive, or other suitable adhesive), and / or other suitable sealing material. This prevents the expansion material 48 from being activated and expanding while one or more longitudinal seals 108 and / or one or more transverse seals 110, 116 are being activated.

[0068] In this embodiment, one or more transverse seals 110, 116 are located at positions spaced apart in the longitudinal direction of the expansion wall 38 and extend substantially entirely across the expansion wall 38 between the longitudinal ends 112 of the expansion wall 38. In other embodiments, one or more of the transverse seals 110, 116 alternately extend over a portion of the transverse length of the expansion wall 38. The transverse seals 110, 116 are separated by gaps 168 spaced 170 apart. According to some embodiments, the gaps 168 are configured to function as vents to release one or more gases generated during the expansion and solidification process of the expansion material 48.

[0069] As shown in Figure 9B, cross-sections of folded expansion walls 38 according to various embodiments of the present disclosure are illustrated exemplarily. The expansion wall 38 includes a space or wall cavity 172 between first and second prisms 32, 34 that contain an expansion material 48, such that the space between the first and second prisms increases as the expansion material 48 expands. The expansion wall 38 is folded at a folding end 166 to form a bag-forming body having an internal cavity 138. One side of the folded expansion wall 38 is folded over, and the other side is sealed via a longitudinal seal 108 to form a seam. The longitudinal seal 108 includes one or more pressure-activated seals, such as a heat-activated seal (e.g., a heat-activated adhesive or other suitable heat-activated seal), one or more strip seals, or pressure-activated seals of any suitable type, such as a pressure-activated adhesive or other suitable type of pressure-activated seal. The sealing material may be applied around the periphery. In some embodiments, the sealing material has a substantially uniform width. In some embodiments, the sealing material is applied with varying widths. The expansion wall 38 may have one folded end 166, or it may have multiple folded ends 166.

[0070] When folded and flattened, the longitudinal seal 108 is positioned. In some embodiments, the seal 108 is positioned at the longitudinal end 112 of the expansion wall 38, as shown in Figure 9A. In other embodiments, the seal 108 is positioned between a plurality of folded ends 166, as shown in Figures 10A–10C, forming a seam 174 on the unfolded longitudinal end 112 of the web. The expansion wall 38 includes one or more brittle regions 134 extending laterally (e.g., roughly perpendicularly) with respect to the longitudinal end 112. The seam 174 includes a longitudinal end 112 that overlaps with another longitudinal end 112, allowing sealing material to be applied to the upper region of one longitudinal end and / or the lower region of the other longitudinal end to form the seal 174. In some embodiments, the seal 174 can be a fin seal or other suitable sealing configuration.

[0071] In this embodiment, one or more transverse seals 110 are provided at positions spaced apart in the longitudinal direction of the expansion wall 38 and substantially extend laterally across the expansion wall 38 between its longitudinal ends 112. In other embodiments, one or more transverse seals 110 extend over a portion of the lateral length of the expansion wall 38.

[0072] As shown in Figures 10A to 10C, the expansion wall 38 includes first and second overlapping pies including a hinge region 178, which is positioned to fold the overlapping pies together at a fold or hinge line 180 extending through the hinge region 178, dividing the overlapping pies 32, 34 into a plurality of wall sections 184 on the opposite side of the hinge line 180. This results in a configuration where the wall sections fold around the hinge line 180, defining an internal cavity 138 between them, which is configured to receive and contain articles. The expansion material 48 is positioned between the first and second pies in the main pad region 182, and the hinge region between the pies has less expansion material than the main pad region 182, so that in the folded configuration, the hinge region is thinner than the main pad region. The web further includes sealing material arranged to adhere the walls in a folded configuration such that the first and second walls define the packaging unit. In some embodiments, the web further includes longitudinal sealing material. In some embodiments, one or both of the longitudinal ends are sealed.

[0073] In some embodiments, the hinge region 178 is substantially free from the inflatable material and provides a gap between portions of the main pad region 182 on the wall portion 184. In some embodiments, the hinge region 178 contains less than 30% of the amount of inflatable material of the main pad region 182. In some embodiments, the hinge region 178 contains less than 25% of the amount of inflatable material of the main pad region 182. In some embodiments, the hinge region 178 contains less than 10% of the amount of inflatable material of the main pad region 182. In some embodiments, the hinge region 178 has no inflatable material. In some embodiments, the hinge region 178 is a longitudinal strip having width. However, the hinge region 178 may have one or more other suitable shapes.

[0074] In some embodiments, the first and second overlapping plies include three wall portions 184, and the hinge region 178 includes a first hinge region 178 located between the first wall portion 188 and the second wall portion 190, and a second hinge region 192 located between the second wall portion 190 and the third wall portion 194, wherein the first wall portion 188 and the third wall portion 194 fold around the hinge 180 in the first and second hinge regions 186, 192, respectively, overlapping with the second wall portion 190, the second wall portion 190 forming the first wall of the packaging container, and the first and third wall portions 188, 194 overlap with the first wall and form the second wall of the packaging container defining an internal cavity 138 between the walls. The sealing material is arranged to seal the first wall to the third wall. In some embodiments, the first and third walls have longitudinal ends such that, in a folded configuration, their longitudinal ends are positioned on top of the second wall and sealed together by a sealing material. In some embodiments, the second wall has a width between hinge lines, and the first and third walls have a cumulative width that is at least the same as the width of the second wall.

[0075] In some embodiments, the first and third wall portions 188, 194 each form a single wall. In some embodiments, the first and third wall portions 188, 194 each include longitudinal ends, and the sealing material is arranged to adhere the wall portions along the longitudinal ends of the first and third wall portions.

[0076] As shown in Figures 11A and 11B, the multiple longitudinal seals 108 are configured to seal multiple expansion walls 38 together. According to this embodiment, the packaging container 93 is formed by sealing multiple expansion walls 38 together, rather than by folding a single expansion wall 38.

[0077] [Supply Configuration]

[0078] Once the expansion wall 38 of the packaging material is formed, the expansion wall 38 is connected to the structure to form a web stock of packaging material. According to some embodiments, the supply structure can be wound onto a supply roll structure 84, as illustrated exemplary in Figures 4A and 15A. The roll structure 84 can be a cored roll structure or a coreless roll structure. Another preferred supply structure is obtained by folding the expansion wall 38 into a fanfold stack structure having opposing folds 86, such as a fanfold (e.g., accordion) structure 85 (as illustrated exemplary in Figure 7A), and / or other suitable structure. Another preferred supply structure is a series of two or more stacked packaging units. As shown in Figure 13, before compaction, the expansion wall 38 is folded into a series of pre-formed packaging containers 93. The expansion wall 38 can be a high-density supply structure 84 (as shown in Figure 4A), and the expandable wall formed by the expansion wall 38 is compacted in an unexpanded structure. In other embodiments, the expansion wall 38 can be a low-density supply configuration 84 (as shown in Figure 4A), and the expansion wall formed by the expansion wall 38 is compacted in the expansion configuration. According to another embodiment, the expansion wall 38 can be a packaging container configuration 196 (as shown in Figure 13), and one or more expansion walls 38 are configured in a series of pre-formed packaging containers 92 and compacted.

[0079] In some embodiments, the supply configuration may be a roll 84 or fanfold stack 85 of expansion walls 38 having one or more brittle regions 134 extending laterally (e.g., roughly perpendicularly) with respect to the longitudinal end 112. The brittle regions allow the panels of the expansion walls 38 to be torn apart for use, for example, as inner packaging for a container.

[0080] [Further processing equipment]

[0081] In some embodiments, once the expansion wall 38 is compacted, it is supplied through a protective packaging machine as shown in Figures 14A and 14B.

[0082] One or more steps in forming a series of bags are performed using protective packaging machines such as the bagging machine / bagger device 200 shown in Figures 14A and 14B, and the bagging machine / bagger device 300 shown in Figures 15A to 15B.

[0083] As shown in Figures 14A and 14B, the bagging machine 200 is supplied with pre-folded and / or sealed inflatable walls 38 so as to include the inflatable walls 38 of a pre-formed bag-forming body. In other embodiments, such as those shown in Figures 15A and 15B, the bagging machine 300 is configured to receive unfolded or unsealed inflatable walls 38 and to form the inflatable walls 38 into one or more packaging container-forming bodies 92.

[0084] If the expansion wall 38 contains an expansion material 48, the bagging machine may expand the expansion material before, during, or after setting the seal by applying heat or other suitable means.

[0085] According to the embodiments shown in Figures 14A to 14B, the bagging machine 200 may be configured to receive the expansion walls 38 of the pre-formed packaging containers 92 and to open the openings 136 of each bag forming body to access the internal cavities 138 of each bag forming body 92.

[0086] In the embodiment shown in Figure 14A, the bagging machine 200 includes a plurality of fingers 202 and / or retractable projections 204 configured to pull open the bag opening 136 and insert one or more products / articles / etc. into the internal cavity 138.

[0087] The expansion wall 38 is supplied to the bagging machine 200 in a non-expanded, high-density configuration. The expansion wall 38 on the supply side of the bagging machine 200 may be a fanfold supply configuration 85 and / or other suitable configurations such as a roll configuration 84. The bagging machine 200 includes a bag handler which includes one or more mechanisms and / or devices for moving the web downstream from the supply through the bagging machine 200. The bag handler may include a bag mover configured to move the expansion wall 38 along the bagging machine 200.

[0088] The bagging machine 200 includes an expansion device 206. If the expansion wall 38 contains an expander 48, the expansion device 206 may include a heating element, a heating coil, a hot air applicator, a high-frequency radiation generator, an ultraviolet applicator, a chemical reaction applicator, a pressure mechanism, or other suitable device for expanding the expander. In some embodiments, such as those shown in Figures 14A and 14B, the expansion device 206 is configured to expand the expandable element before inserting the product into the internal cavity 138. In other embodiments, the expansion device 206 is configured to expand the expandable element following the insertion of the product into the internal cavity 138. In yet another embodiment, the expansion device 206 is configured to expand the expandable element during the insertion of the product into the internal cavity 138.

[0089] As shown in Figure 14A, the expansion device 206 is located upstream of the bagging mechanism 208 to feed the expansion wall 38 to the bagging mechanism 208. The bagging mechanism 208 is configured to seal the bag-forming body and (acting as a separator) separate it from subsequent bag-forming bodies to form individual bags.

[0090] In other embodiments, the inflation device 206 is located in or downstream of the bagging mechanism 208 to inflate the walls of the inflation walls 38 at another point in the bag manufacturing process. In some embodiments, such as those shown in Figure 14B, a printing assembly 210 may be used to print one or more images and / or a portion of one or more data / information onto the inflation walls 38.

[0091] As shown in Figure 14B, the inflation mechanism 206 is configured to inflate the inflation element before opening the bag opening 136 for the insertion of one or more products. In other embodiments, the inflation mechanism 206 is configured to inflate the inflation element simultaneously with or after opening the bag opening 136 for the insertion of one or more products.

[0092] The expansion wall 38 includes one or more brittle regions 134 and one or more openings 136 and is applied before the sealing process. In other embodiments, one or more brittle regions 134 and / or one or more openings 136 are applied during or after the sealing process. The brittle regions 134 are configured to break to separate one packaging container from a subsequent packaging container. The openings 136 are configured and positioned to allow access to the internal cavity 138 of the packaging container form 92 and can be opened by mechanical fingers 202 and / or suction cups 212. Pressurized air can be used to assist in opening the openings 136 of the packaging container form 92.

[0093] The fingers 202 are configured to grip a portion of the packaging container opening 136, opening the packaging container at the opening 136 and providing further securing means for holding the packaging container in place. The bagging machine 200 may include an air blower 214 configured to apply air pressure to the opening 136 to help open the packaging container. The opening 136 may include a pouch seal. The pouch seal may include an adhesive to close and seal the opening 136 once the product is inserted. Other forms of sealing the opening 136, such as a heat seal, may be implemented additionally or alternatively. Once the opening 136 is closed and sealed, the brittle region 134 can be broken, for example, by inverting, cutting, melting, or other suitable means of the next packaging container.

[0094] Each packaging container 92 within the expansion wall 38 can be separated using one or more cutting blades configured to tear apart the embrittlement region 134 located between each packaging container 92 in the series of packaging containers 92 using the tensile force applied to each packaging container 92, or to form a tear along the seam connecting two packaging containers 92 in the series of packaging containers 92. In some embodiments, each packaging container 92 in the series of packaging containers 92 is separated using focused heat configured to melt a portion of the seam connecting two packaging containers 92 in the series of packaging containers 92.

[0095] Referring here to Figures 15A and 15B, the bagging machine 300 is configured to convert the inflated wall 38 into one or more finished packaging containers and seal them. The inflated wall 38 is supplied to the bagging machine 300 in a non-inflated, high-density configuration via a bag handler. The inflated wall 38 can be in a roll configuration 84. The bag handler may include a bag mover configured to move the inflated wall 38 along the bagging machine 300. In other embodiments, the inflated wall 38 may be one or more other non-inflated, high-density configurations, such as a fanfold configuration 85.

[0096] When supplied to the bagging machine 300, the expansion wall 38 passes through an expansion device 206 configured to expand the expandable elements of the expansion wall 38. According to some embodiments, the expansion wall 38 includes one or more hinge lines 166, 178, these hinge lines 166, 178 include a section 304 of the expansion wall 38 that is not expanded, contains little to no expansion material, or contains no expansion material, forming a natural hinge that facilitates the folding of the expansion wall 38. In some embodiments, the lines of the expansion wall 38 can be left without expansion material 48 to form a natural hinge line or a region that is more easily bent than other areas where expansion material 48 is expanded. In some embodiments, pressure is applied to the expansion material 48 during or after expansion to form a hinge line or region 55 in section 304 that is more easily bent than other areas.

[0097] The inflated expansion wall 38 is fed through a folding device / bag holder 306 configured to fold the expansion wall 38 so that its longitudinal ends contact each other. The folding device 306 may include one or more folding bars 308 configured to fold the expansion wall 38 into a C-fold formation. The folding device 306 can fold the expansion wall 38 along a hinge region 178 or in one or more other sections. The folding device 306 may further include a crossbar 310 configured to align the expansion wall 38 so that the folded expansion wall 38 forms an internal cavity 312. Once folded, a set of retaining mechanisms (e.g., fingers 314) hold the expansion wall 38 open, allowing one or more products to be placed in the internal cavity 312. In Figure 15B, the web is positioned vertically, while the products are positioned horizontally in the internal cavity 312, with the opening oriented transverse to the longitudinal direction of the expansion wall. In other embodiments, the expansion wall may be positioned horizontally or at another suitable angle (for example, such that the opening to the internal cavity 312 faces upward).

[0098] Once the product is placed in the internal cavity 312, the expansion wall 38 is fed into a sealing mechanism 316 configured to seal the longitudinal and transverse seals of the expansion wall 38. The sealing mechanism 316 may be configured to apply heat, pressure, and / or other suitable means to set the seal. In some embodiments, the sealing mechanism 316 is configured to pull the web through the bagging machine 300 for sealing. Once sealed, the expansion wall 38 is transformed into a formed and sealed bag 302. According to some embodiments, the bagging machine 300 includes a separation mechanism 318 configured to separate the packaging container 92 from the expansion wall 38. In some embodiments, the separation mechanism 318 is configured to pull the finished bag 320 and tear the finished bag 320 from subsequent bags along the brittle region 134. In some embodiments, the separation mechanism 318 is configured to separate the bag 320 via cutting through a blade or heat. In some embodiments, the separation mechanism 318 may incorporate other suitable separation means. According to some embodiments, the separation mechanism 318 is configured to hold the bag 302 in place so that the sealing mechanism 316 can seal the subsequent bag.

[0099] In some embodiments, the bagging machine may process already inflated expansion wall 38 supply material, or it may include an expansion device that inflates the material before, during, or after the production of the packaged product. In some embodiments, the bagging machine may be configured to process individual mailers or bags rather than stock expansion wall 38 supply material.

[0100] This disclosure is not limited in terms of the specific embodiments described herein, which are intended as illustrative examples of various embodiments. As will be apparent to those skilled in the art, many modifications and embodiments can be made without departing from its spirit and scope. In addition to those enumerated herein, functionally equivalent methods and apparatus within the scope of this disclosure will be apparent to those skilled in the art from the foregoing description. Such modifications and embodiments are intended to fall within the scope of the appended claims. This disclosure is limited only by the conditions of the appended claims, along with the scope of the complete equivalents to which such claims are entitled. It will also be understood that the terms used herein are for illustrative purposes only and are not intended to limit any particular embodiment.

[0101] With regard to the use of substantially any plural and / or singular terms herein, those skilled in the art can convert from plural to singular and / or singular to plural as appropriate to the context and / or application. Various singular / plural rearrangements may be explicitly described herein for clarity.

[0102] [CROSS-REFERENCE TO RELATED APPLICATION] This application claims priority to U.S. Provisional Patent Application No. 62 / 706,110, filed on 31 July 2020, entitled “METHOD OF MAKING AN EXPANDABLE WEB”. Preferred systems and methods for manufacturing protective packaging having an expandable web are disclosed in U.S. Patent Application No. 17 / 365,548, filed on 1 July 2021, entitled “PACKAGING WITH SEALING MATERIALS HAVING DIFFERENT SEALING CONDITIONS”, U.S. Patent Application No. 17 / 365,892, filed on 1 July 2021, entitled “BAGGER WITH PADDING EXPANSION”, and U.S. Patent Application No. 17 / 365,854, filed on 1 July 2021, entitled “USER-EXPANDABLE PACKAGE”, all of which are incorporated herein by reference.

Claims

1. A method for manufacturing an expandable wall in a non-expanded state, Apply the matrix to the first ply, An expansion element is applied to the surface of the matrix, To contain the matrix and the expansion element, a second ply is placed on top of the first ply. This includes inserting the coated expansion element into the coated matrix to form an unexpanded expansion material, A method for manufacturing an expandable wall, wherein the unexpanded expandable material is configured to expand and solidify when activated.

2. The method according to claim 1, wherein the expanding material is configured to provide a pad between the first ply and the second ply when it expands and solidifies.

3. The method according to claim 1, wherein when the expansion element is activated, the matrix expands and solidifies.

4. Inserting the expansion element into the matrix includes compressing the first and second plies together to push the expansion element into the matrix. The method according to claim 1, wherein when the expansion element is activated, it expands the matrix, thereby increasing the spacing between the first ply and the second ply.

5. The method according to claim 1, wherein the expansion element includes fine particles that adhere to the surface of the matrix when applied to the surface of the matrix.

6. During the coating of the fine particles onto the surface of the matrix, the fine particles that did not adhere to the matrix are collected. To provide an additional matrix on the first ply having the recovered microparticles on its surface, the recovered microparticles are recoated onto the surface of the additional matrix. The method of claim 5, wherein the first ply and the second ply are compressed with respect to the additional matrix and the recoated fine particles.

7. The method according to claim 6, wherein the collection of the fine particles includes a vacuum device having sufficient strength to suck up the fine particles without damaging the matrix having an expansion element on the first ply or its surface.

8. The method according to claim 1, wherein the application of the expansion element includes a coating apparatus that sprays the expansion element toward the first ply and the matrix and randomly disperses the expansion element.

9. The method according to claim 1, wherein the expansion element is applied to the matrix before the matrix is ​​applied to the first ply.

10. The method according to claim 1, wherein the expansion element comprises a plurality of microspheres containing a material from which gas is released when activated.

11. The method according to claim 1, wherein the matrix is ​​a fluid.

12. A method for producing an expanded wall by activating the expansion element of the expandable wall produced by the method of Claim 1.

13. The method according to claim 12, wherein the activation of the expansion element includes irradiating it with radiation.

14. The method according to claim 12, wherein the activation of the expansion element is caused by a chemical reaction.

15. The method according to claim 1, wherein the first ply and the second ply include paper.

16. The method according to claim 1, further comprising folding a single web of sheet material along the fold line in order to define the first and second plies on the opposite side of the fold line.

17. The method according to claim 1, wherein the first and second plies are formed from separate sheets of a single web of sheet material.

18. The method according to claim 1, wherein the matrix is ​​a starch-based adhesive.

19. The method according to claim 1, wherein the first and second plies include longitudinal ends that align when the second ply is placed over the first ply.

20. The method according to claim 1, further comprising: the second ply being placed over the expandable wall to form the expandable wall into a dense supply configuration.

21. The method according to claim 20, wherein the coated expansion element is inserted into the matrix by forming the dense supply configuration of the expandable wall.

22. The method according to claim 21, wherein the formation of the dense supply configuration of the expandable wall includes making the expandable wall roll-shaped or fan-fold-shaped.

23. The method according to claim 1, further comprising: extending transversely across one or both of the first ply and the second ply to form a brittle region configured to facilitate the separation of portions of the first ply and the second ply from one another.

24. The second ply is placed over the expandable wall, and the method is, To position the first side of the expandable wall relative to the second side of the expandable wall, the expandable wall is folded along the fold line, The method according to claim 1, further comprising sealing the first side of the inflatable wall to the second side of the inflatable wall so as to define an internal cavity configured to receive an article to be packaged between the first side and the second side.

25. The method according to claim 24, wherein the expandable wall is configured such that when the expansion element is activated, a padded container including the internal cavity is formed.

26. The method according to claim 1, wherein the expansion element is applied to the surface of the coated matrix.

27. Applying the matrix includes dispensing the matrix, The method according to claim 1, wherein applying the expansion element involves dispensing the expansion element to apply the expansion element to the surface of the dispensed matrix as the dispensed matrix is ​​moving toward the first ply such that the matrix has the expansion element on its surface and is applied to the first ply.

28. The matrix is ​​discharged by ejecting the matrix in a trajectory toward the first ply, The method according to claim 27, wherein the expansion element is applied to the discharged matrix as the matrix moves along the trajectory.

29. The method according to claim 1, wherein the matrix is ​​applied to the first ply, and then the expansion element is applied to the matrix.

30. A method for producing an expandable web in an unexpanded state, The matrix is ​​applied to the first ply by dispensing using a matrix coating device. After the matrix is ​​dispensed from the matrix coating apparatus, and before the matrix is ​​applied to the first ply, an expansion element is applied to the surface of the applied matrix to provide an expansion material. This includes placing a second ply over the first ply so as to confine the matrix and the expansion element between them, A method for manufacturing a web, wherein the web is configured such that when the expansion element is activated, the matrix expands and solidifies, providing a pad between the first ply and the second ply.

31. The method according to claim 30, further comprising using an apparatus to move the first ply having the coated matrix so that the expansion element is coated onto the matrix coated on the first ply being moved.

32. The method according to claim 30, further comprising inserting the coated expansion element into the coated matrix.

33. A method for producing an expanded wall web, comprising activating the expansion elements of a web produced by the method of claim 30, thereby producing an expanded wall web.

34. An apparatus for manufacturing an expandable web in an unexpanded state, wherein the apparatus is: A matrix applicator for applying a matrix to the first ply, An expansion element applicator for applying expansion elements to the surface of the matrix, An apparatus comprising: an intake device for inserting the coated expansion element into the matrix such that the matrix expands upon activation of the expansion element and solidifies in an expanded state.

35. The apparatus according to claim 34, An apparatus for producing an expanded wall web, comprising an expansion activation device for activating the expansion element and causing expansion of the expansion material.

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