Segmented Seal Films for Inflatable Cushion Leakage and Waste
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Solution Overview
Problem
Existing film configurations for inflated cushions often waste material, inhibit separation of adjacent cushions, and are susceptible to under-inflation or leakage, limiting their utility in packaging applications.
Innovation Solution
The film configuration includes a pair of web layers with longitudinal and transverse seals that define inflatable chambers, allowing for efficient inflation and separation of cushions, with features like skirts and transverse lines of weakness to facilitate handling and minimize material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional seal configurations are used, then the film can be manufactured with simple sealing processes, but material is wasted and separation of adjacent cushions is inhibited
Solution Approach 1:
The seal configuration is segmented into multiple discrete seal regions (first seal region, second seal region, third seal region) positioned at different locations. This segmentation allows each seal to serve a specific function: the first seal prevents leakage, the second seal enables separation, and the third seal provides structural support, thereby eliminating material waste while maintaining manufacturing simplicity
Solution Approach 2:
Different regions of the seal configuration have different properties and functions. The first seal region has high sealing density for leakage prevention, the second seal region has spaced-apart configuration for separation, and the third seal region has structural reinforcement. This local differentiation optimizes material usage while maintaining ease of manufacture
2Device complexity
If traditional seal configurations are used, then the film structure can be simple, but adjacent cushions cannot be separated effectively
Solution Approach 1:
The seal configuration is divided into distinct functional zones, with the second seal region specifically positioned to facilitate separation. This segmentation allows the film structure to remain relatively simple while the spaced-apart configuration of the second seal region enables easy separation of adjacent cushions during use
Solution Approach 2:
The second seal region acts as an intermediary element between adjacent cushions, providing a controlled separation path. This intermediate seal configuration allows cushions to be separated from each other while maintaining the overall integrity of the film structure
3Ease of manufacture
If traditional seal configurations are used, then the film can be manufactured with standard sealing processes, but inflated cushions are susceptible to under-inflation or leakage
Solution Approach 1:
The sealing system is segmented into multiple independent seal regions that work together. The first seal region provides primary leakage prevention, the second seal region maintains pressure differential, and the third seal region provides structural reinforcement. This multi-region segmentation enhances reliability while allowing standard sealing processes to be used
Solution Approach 2:
The seal configuration includes preventive measures built in beforehand, with the first seal region positioned to prevent leakage before it occurs and the third seal region providing structural reinforcement to prevent under-inflation. These preemptive sealing features ensure reliability while maintaining ease of manufacture
Data Source
AI summary
Films for inflatable cushions are disclosed. Generally, each of the disclosed films includes a pair of web layers that are aligned to be generally coextensive and that are sealed together by longitudinal and/or transverse seals that cooperatively define the boundaries of inflatable chambers.