Perforated Thermoplastic Web for Dunnage Inflation
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Solution Overview
Problem
Prior art plastic webs for forming dunnage units have perforations that extend to the inflation edge, causing undesirable stresses and wrinkles during inflation, which can compromise the seal and limit the efficiency of separating adjacent units.
Innovation Solution
A plastic web with spaced transverse seals and lines of perforations that create a gap between adjacent pouches, allowing for easier separation and reduced stresses during inflation, with the gap forming area designed to rupture at a lower force than the main perforations, facilitating fuller inflation and a more reliable seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If perforations extend all the way to the inflation edge, then adjacent dunnage units can be separated, but undesirable stresses and wrinkles occur during inflation that compromise the seal
Solution Approach 1:
The web is divided into distinct functional zones: a first line of perforations for unit separation and a second line of perforations for inflation opening, with the second line spaced away from the inflation edge. This segmentation allows each perforation line to perform its specific function without interfering with the seal integrity at the inflation edge.
Solution Approach 2:
A line of perforations spaced away from the inflation edge acts as an intermediary structure that provides a controlled opening mechanism without directly compromising the seal area. This intermediary perforation line allows inflation to occur while maintaining a buffer zone that protects the seal from excessive stress and wrinkling.
2Device complexity
If perforations extend to the inflation edge, then inflation can occur, but wrinkles develop at the inflation opening that compromise the seal
Solution Approach 1:
The problematic extension of perforations to the inflation edge is extracted and removed. Instead, a second line of perforations is positioned at a distance from the inflation edge, eliminating the source of wrinkles while preserving the inflation function through the first perforation line.
3Reliability
If gap forming area ruptures at lower force, then fuller inflation is achieved, but requires precise control of rupture force
Solution Approach 1:
The web structure incorporates localized variations in perforation characteristics: the first line of perforations has different spacing and/or depth characteristics compared to the second line, and the gap forming area has distinct properties that cause it to rupture at lower forces. This local differentiation enables controlled inflation without requiring complex manufacturing adjustments across the entire web.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easier separation of dunnage units, reduces undesirable stresses during inflation, and results in a more reliable seal by creating a gap between adjacent pouches, allowing for fuller inflation and minimizing wrinkles at the inflation opening.
Implementation Method 1
the gap forming area designed to rupture at a lower force than the main perforations
Data Source
AI summary
A preformed web and a method of producing dunnage units from the preformed web. The web is an elongate flattened thermoplastic tube having an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of perforations that allow adjacent dunnage units to be separated. A starting point of the lines of perforations is spaced apart from the inflation edge.