Note: Descriptions are shown in the official language in which they were submitted.
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ON-DEMAND INFLATABLE PACKAGING
CROSS-REFERENCE TO RELATED APPLICATION
10011 This application claims the benefit of United States Provisional
Patent
Application Serial No. 62/270,205, entitled ON-DEMAND INFLATABLE PACKAGING and
filed, December 21, 2015, which incorporated herein by reference in its
entirety.
BACKGROUND
[002] Bubble wrap is a widely-used packaging material. One known use of
bubble
wrap is as a cushioning material, for example, wrapped around a product or
within a larger
package, such as within corrugate, a bag, or paper. For example, cushioning
material is used
within the inside of a paper skin as a padded envelope.
[003] A typical padded envelope includes cushioning material formed by a
vacuum
process. After the two layers of plastic are laminated or sealed together, a
small amount of air is
trapped within each bubble to create a cushioning characteristic.
[004] Conventionally, a padded envelope is manufactured at assembly site.
At the
assembly site, the cushioning material is formed and attached to the paper
skin. The envelope
may be shipped to a point of retail sale, or a product may be packed within
the padded envelope
at a packing site. In either example, the padded envelopes are shipped in a
final size and volume,
i.e., with the inflation pattern fully inflated.
SUMMARY
[005] The present application describes a method of making packages. In an
exemplary embodiment, a method of making packages may include moving a web of
preformed
inflatable bags along a path of travel. The preformed inflatable bags include
two inflatable
panels, and each inflatable panel includes a first ply and a second ply that
are sealed together to
form an inflation pattern. The method may include inflating each of the
preformed inflatable
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bags, sealing each of the preformed inflatable bags across the seals of the
inflation pattern,
depositing at least one product into each of the preformed inflatable bags,
and loading each of
the preformed inflatable bags and contained product into a non-inflatable bag.
[006] Further features and advantages of the invention will become apparent
from the
following detailed description made with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[007] Features and advantages of the general inventive concepts will become
apparent from the following detailed description made with reference to the
accompanying
drawings.
[008] Figure 1 is a perspective view of an exemplary embodiment of an
inflatable
packaging web;
[009] Figure 2 is a sectional view of the packaging web of Figure 1, shown
along the
line 2-2 of Figure 1;
[010] Figure 2A is a view similar to the view of Figure 2, where the
packaging web
has two inflation channels;
[011] Figure 3 is a side view of another exemplary embodiment of an
inflatable
packaging web, showing a pouch in an inflated condition;
[012] Figure 3A is a side view of the inflatable packaging web of Figure
2A,
showing a pouch in an inflated condition;
[013] Figure 4 is a side view of the pouch of Figure 3, showing the pouch
in a closed
position;
[014] Figure 5 is a top view of sequential assembly stages of a method to
make an
exemplary embodiment of an inflatable packaging web;
[015] Figure 6a is a sectional view of another exemplary embodiment of an
inflatable
packaging web, showing a pouch in an inflated condition;
[016] Figure 6b is a sectional view of the pouch of Figure 6a, showing the
pouch in a
sealed condition;
[017] Figure 6C is a sectional view an inflatable packaging web that is
similar to the
Figure 6a embodiment, except the inflatable packaging web includes two
inflation channels,
showing a pouch in an inflated condition;
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[018] Figure 6D is a sectional view of the pouch of Figure 6C, showing the
pouch in
a sealed condition;
[019] Figure 7 is a front view of the pouch of Figure 6b, showing bar code
data and
indicia imprinted on the pouch;
[020] Figure 8a is a front view of another exemplary embodiment of an
inflatable
packaging web;
[021] Figure 8b is a sectional view of the inflatable packaging web of
Figure 8a,
shown along the line 8b-8b of Figure 8a;
[022] Figure 8c is a sectional view of the inflatable packaging web of
Figure 8a,
shown along the line 8c-8c of Figure 8a;
[023] Figure 8D is a front view of another exemplary embodiment of an
inflatable
packaging web;
[024] Figure 8E is a sectional view of the inflatable packaging web of
Figure 8D,
shown along the line 8E-8E of Figure 8D;
[025] Figure 8F is a sectional view of the inflatable packaging web of
Figure 8a,
shown along the line 8F-8F of Figure 8D;
[026] Figure 9 is a sectional view of the inflatable packaging web of
Figure 8a,
showing a pouch in an inflated condition;
[027] Figure 9A is a sectional view of the inflatable packaging web of
Figure 8D,
showing a pouch in an inflated condition;
[028] Figure 10 is a sectional view of the pouch of Figure 9, showing the
pouch in an
inflated condition with the panel sealed;
[029] Figure 10A is a sectional view of the pouch of Figure 9A, showing the
pouch
in an inflated condition with the panel sealed;
[030] Figure 1 la is a sectional view of another exemplary embodiment of an
inflatable packaging web, showing a pouch in an inflated condition with the
panel sealed and
with the skin closed;
[031] Figure lib is a front view of the pouch of Figure 11a, showing bar
code data
and indicia imprinted on the pouch;
[032] Figure 12 is a front view of another exemplary embodiment of an
inflatable
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packaging web;
[033] Figure 13 is a sectional view of the inflatable packaging web of
Figure 12,
shown along the line 13-13 of Figure 12;
[034] Figure 14 is a sectional view of the inflatable packaging web of
Figure 12,
shown along the line 14-14 of Figure 12;
[035] Figure 15 is a sectional view of the inflatable packaging web of
Figure 13,
showing the sealed skin in a slit condition;
[036] Figure 16 is a sectional view of the inflatable packaging web of
Figure 13,
showing the sealed skin in a slit condition and the skin flaps folded open;
[037] Figure 17 is a sectional view of the inflatable packaging web of
Figure 13,
showing a product inserted inside;
[038] Figure 18 is a sectional view of the inflatable packaging web of
Figure 17,
showing a the web in an inflated condition;
[039] Figure 19 is a sectional view of the inflatable packaging web of
Figure 18,
showing a the web in an inflated condition and the panel sealed;
[040] Figure 20 is a sectional view of the inflatable packaging web of
Figure 19,
showing the skin flaps closed;
[041] Figure 21a is a front perspective view of a packaging machine,
showing
exemplary machinery for forming and packaging a padded package from an
inflatable packaging
web;
[042] Figure 21b is a top view of a packaging machine of Figure 21a;
[043] Figure 22 is a schematic view of a process of forming inflatable
cushioning
material;
[044] Figure 23 is a top view of a web of inflatable cushioning material
being
produced by the process of Figure 22;
[045] Figures 24a-24e illustrate an exemplary method of moving a web of
inflatable bags along a path of travel to make packages;
[046] Figures 25a-25e illustrate another exemplary method of moving a web
of
inflatable bags along a path of travel to make packages;
[047] Figure 26 illustrates an exemplary packaging machine used to load an
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inflated bag and product into a non-inflatable bag;
[048] Figures 27A-27C illustrate another exemplary packaging machine used
to load an inflated bag and product into a non-inflatable bag;
[049] Figures 28A-28E illustrate an exemplary method of moving a web of
inflatable bags along a path of travel to make packages; and
[050] Figures 29A-29E illustrate another exemplary method of moving a web
of inflatable bags along a path of travel to make packages.
DETAILED DESCRIPTION
[051] This Detailed Description merely describes exemplary embodiments in
accordance with the general inventive concepts and is not intended to limit
the scope of the
invention or the claims in any way. Indeed, the invention as described by the
claims is broader
than and unlimited by the exemplary embodiments set forth herein, and the
terms used in the
claims have their full ordinary meaning.
[052] The general inventive concepts will now be described with occasional
reference to the exemplary embodiments of the invention. This general
inventive concept may,
however, be embodied in different forms and should not be construed as limited
to the
embodiments set forth herein. Rather, these embodiments are provided so that
this disclosure
will be thorough and complete, and will fully convey the scope of the general
inventive concepts
to those skilled in the art.
[053] Unless otherwise defined, all technical and scientific terms used
herein have
the same meaning as commonly understood by one of ordinary skill in the art
encompassing the
general inventive concepts. The terminology set forth in this detailed
description is for
describing particular embodiments only and is not intended to be limiting of
the general
inventive concepts. As used in this detailed description and the appended
claims, the singular
forms "a," "an," and "the" are intended to include the plural forms as well,
unless the context
clearly indicates otherwise.
[054] Unless otherwise indicated, all numbers expressing quantities of
ingredients,
properties such as molecular weight, reaction conditions, percentages and so
forth as used in the
specification and claims are to be understood as being modified in all
instances by the term
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"about." Accordingly, unless otherwise indicated, the numerical properties set
forth in the
specification and claims are approximations that may vary depending on the
suitable properties
sought to be obtained in embodiments of the present invention. Notwithstanding
that the
numerical ranges and parameters setting forth the broad scope of the general
inventive concepts
are approximations, the numerical values set forth in the specific examples
are reported as
precisely as possible. Any numerical values, however, inherently contain
certain errors
necessarily resulting from error found in their respective measurements.
[055] When discussing the invention, a final packaging product is
discussed. For
exemplary purposes, a padded mailer envelope is discussed. However, it should
be apparent to
one with ordinary skill in the art, that the invention may be practiced with
other packaging
products, such as for example, paper or plastic bags, paper or plastic
mailers, corrugate mailers,
and other know packaging offerings in which the inside of the package may be
lined with a
cushioning material.
[056] The invention is directed to a method of producing on-demand
inflatable
packaging. The packaging would include a web of preformed pouches being
defined by side
edges and two panels. At least one panel has an inflation pattern and an outer
skin may be
attached to the outside of the web, or an outside surface of the panels may be
smooth to act as an
outer skin. The packaging would be inflatable at a later time for assembly of
a padded envelope,
either with or without a product being deposited in the preformed pouch, and
the product being
deposited before or after the preformed pouch is inflated.
[057] The inventive assembly of the on-demand inflatable packaging allows
the
inflating of the padded envelope to be delayed, such as for example, until the
end-user of the
envelope deposits a product into the pouch. After the web is inflated, the
padded envelope is
separated from the web. This method allows more padded envelopes, in a non-
inflated
condition, to be shipped having a specific volume and weight, as compared to
inflated padded
envelopes. Also, a final user of the padded envelopes, such as a packer of a
product, may
produce only the amount of inflated padded envelopes needed for a certain
packaging run, and
thus enjoy the efficiencies of just-in-time production and reduction of
envelope inventory.
[058] In one embodiment of the invention, a method converts a web of
preformed
pouches to on-demand inflatable packaging. The pouches are defined by side
edges, two panels,
and at least one panel having an inflation pattern. The method includes moving
the web along a
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path of travel, attaching an outer skin to the outside of the web, and
packaging the web into a
non-inflated and stored configuration. The web may be at least partially
deflated and flattened
before packaging. At the same or another location, the method may include
moving the web
along a path of travel, inflating each of the preformed pouches, and sealing
each of the
preformed pouches to form a cushioning material. In this condition, the two
panels of each
pouch are positioned to define an open end of the pouch and a closed end of
the pouch.
[059] After the cushioning material is formed, the method may include
closing each
of the preformed pouches, sealing the outer skin in a closed position around
each of the
preformed pouches, and separating the web into a plurality of padded
envelopes. The preformed
pouches may be closed before the outer skin is closed, or the preformed
pouches and the outer
skin may be closed at the same time. The outer skin may be attached to the web
by heat sealing,
during the edge line perforation process, or any known technique. In one
embodiment, the outer
skin is attached to the web at edge lines of the preformed pouches and
unattached at areas
between the edge lines of the preformed pouches. In another embodiment, the
outer skin is
attached to the web at areas between the edge lines of the preformed pouches.
[060] In another embodiment, at least one product is deposited into each of
a
plurality of the preformed pouches. This embodiment includes inflating each of
the preformed
pouches, either before or after the product is deposited, sealing each of the
preformed pouches to
form a cushioning material, closing each of the preformed pouches, sealing the
outer skin in a
closed position around each of the plurality of the preformed pouches, and
separating the web
into a plurality of padded envelopes. The preformed pouches may be closed
before the outer
skin is closed, or the preformed pouches and the outer skin may be closed at
the same time.
[061] In another embodiment, a method of assembly for on-demand inflatable
packaging includes an intermediate sealing of the outer skin, and after a time
in storage,
separating the outer skin. The method includes moving the web along a path of
travel, attaching
an outer skin to the outside of the web, sealing the outer skin in a closed
position on the outside
of the web, and packaging the web into a non-inflated and stored
configuration. In this stored
configuration, an amount of on-demand inflatable packaging, transferrable into
a given number
of envelopes, is storable in a smaller volume than the same number of fully
inflated envelopes.
[062] The method may further include moving the web along a web of travel,
separating the outer skin open to thereby open the preformed pouches for
inflation, and inflating
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the preformed pouches. After inflation, the preformed pouches are sealed to
form a cushioning
material. The method may further include sealing the outer skin in a closed
position on the
outside of the web and separating the web into a plurality of padded
envelopes, or depositing at
least one product into each of a plurality of the preformed pouches, sealing
the outer skin in a
closed position on the outside of the web, and separating the web into a
plurality of padded
envelopes.
[063] When the intermediate sealed skin is separated to an open position,
the sealed
skin may form flaps on either side of the preformed pouch opening. Further,
the method may
include forming sealable flaps on either side of the preformed pouches after
cutting the outer
skin open to thereby open the preformed pouches for inflation forms sealable
flaps, pulling the
sealable flaps open in opposing directions, and depositing at least one
product into each of a
plurality of the preformed pouches.
[064] After depositing, the method may include closing each of the
preformed
pouches, sealing the outer skin in a closed position around each of the
preformed pouches, and
cutting the web into a plurality of padded envelopes. The preformed pouches
may be closed
before the outer skin is closed, or the preformed pouches and the outer skin
may be closed at the
same time.
[065] Another embodiment of the invention is a method of making packages
with a
preformed inflatable bag without an outer skin and with a non-inflatable bag.
In this
embodiment, a web of preformed inflatable bags move along a path of travel.
The preformed
inflatable bags include two inflatable panels, and each inflatable panel
includes a first ply and a
second ply that are sealed together to form an inflation pattern. The method
includes inflating
each of the preformed inflatable bags, sealing each of the preformed
inflatable bags across the
seals of the inflation pattern, depositing at least one product into each of
the preformed inflatable
bags, and loading each of the preformed inflatable bags and contained product
into a non-
inflatable bag. In one embodiment, the product is deposited into the preformed
inflatable bag
after the preformed inflatable bag is inflated and sealed. In another
embodiment, the product is
deposited into the preformed inflatable bag prior to the preformed inflatable
bag being inflated
and sealed.
[066] Another embodiment of the invention is preformed and inflatable
pouches for
manufacture into a plurality of padded envelopes. The pouches include a web of
pouches being
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defined by side edges, two panels, and at least one panel having an inflation
pattern, an outer
skin attached to the outside of the web. The web is packaged into a non-
inflated and stored
configuration.
[067] The outer skin may be attached to the web at edge lines of each pouch
and
unattached at areas between the edge lines of the pouches, or the outer skin
may be attached to
the web at areas between the edge lines of the pouches. In the non-inflated
and stored
configuration, the outer skin may be sealed in a closed position on the
outside of the web with
the two panels of each pouch open to define an open end and a closed end.
[068] The web of preformed pouches may be of a variety of forms in the
practice of
the invention. The web may be an inflatable cushioning material designed to be
inflated initially,
flattened, and re-inflated at a later time by an end user and used as a
wrapping material. An
exemplary material is FASTWRAPTm, manufactured and marketed by Automated
Packaging
Systems of Streetsboro, Ohio, and described in US Patent No. 6,423,166, which
is incorporated
herein by reference in its entirety. The end user inflates this material on-
demand and inflates
only the amount of wrapping material that is required at that time. A method
of producing the
preformed pouches is discussed herein.
[069] The outer skin may be made of any thin material of suitable strength.
Exemplary materials for the outer skin include paper and plastic and the
material may be
printable. For example, a plastic skin may be imprinted with indicia, such as
for example,
trademark information, product measurements, instructions, and bar coding
data. The outer skin
remains sufficiently smooth after all manufacturing steps, such as for
example, initial inflation,
flattening, and re-inflation, so that the bar coding is readable by a scanner.
[070] The outer skin may be sealed on all four sides around the perimeter
of the
preformed pouch. If the end user of the on-demand inflatable packaging
produces packaging as
an end product, such as for example, padded mailing envelopes, the outer skin
may be sealed on
only three sides around the perimeter of the envelope to allow for depositing
of a product. The
open side may include user sealable features, such as for example, a removable
strip which
temporarily protects an adhesive strip.
[071] Referring now to the drawings, Figures 1 and 2 illustrate an
exemplary
embodiment of an inflatable packaging web 10. An exemplary web is made of one
or more
layers of plastic film. The packaging web 10 includes a string of side
connected inflatable
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pouches or bags 12. A single pouch 12 is shown in Figure 1, but the web 10
includes an
indeterminate length of inflatable pouches or bags 12. Each inflatable pouch
is connected to one
another at side edges 14. The exemplary side edges shown include lines of
perforations 16 to
facilitate separation of the finished product. Each pouch 12 includes at least
one inflatable panel
18. The inflatable panel can take a wide variety of different forms. In
exemplary embodiments,
the panels 18 may be at least partially inflated, at least partially
flattened, and then fully inflated.
The panels may be made from the web disclosed in US Patent No. D596,031 or the
web
disclosed in US Patent No. 6,423,166, each of which are incorporated herein by
reference in their
entirety.
[072] An exemplary web of on-demand inflatable packaging includes two or
more
inflatable bags. Each inflatable bag 12 includes two inflatable panels 18, and
each inflatable
panel includes a first ply 17 and a second ply 19. The first ply 17 and second
ply 19 of each
panel 18 may be sealed together to form an inflation pattern. One or both of
the panels 18
include an inflation pattern 512 (see Figure 5). One (See Figure 2) or both
(See Figure 2A) of
the panels 18 include an inflation channel 30. The inflation channel allows
the preformed
inflatable bag to be inflated by a nozzle inserted into the channel 30.
[073] In the illustrated embodiment in Figure 2, only one inflation channel
30 is
included and the two panels of the inflatable bag are in fluid communication,
such that inflation
of one of the panels inflates the other panel. For example, in the illustrated
embodiment
passages 32 connect the air pockets 34 (see Figure 3) at the bottoms of the
panels to one another
such that inflation through the inflation channel 30 causes inflation of both
panels. The inflation
channel 30 may be as described by any one or more of US Patent Nos. 6,423,166;
8,357,439;
D646,972, 8,038,348, each of which are incorporated herein by reference in
their entirety.
[074] In the illustrated embodiment in Figure 2A, two inflations channels
30 are
included and the two panels of the inflatable bag are optionally isolated in
fluid communication,
for example by an optional seal 33. For example, in the illustrated embodiment
a seal or seals 33
isolate the air pockets 34 (see Figure 3A) at the bottoms of the panels such
that deflation of one
panel does not cause deflation of both panels. The inflation channel 30 may be
as described by
any one or more of US Patent Nos. 6,423,166; 8,357,439; D646,972, 8,038,348,
each of which
are incorporated herein by reference in their entirety.
[075] The web of preformed inflatable bags 12 may be inflated to produce
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cushioning material. The inflatable bag 12 may be inflated and sealed in a
first step to maintain
the cushioning material, and then closed to create a closed inflated bag 50.
For example, Figures
3 and 4 illustrate an inflatable bag 12 of the web in an inflated condition.
The web 10 is inflated
through the inflation channel 30 and sealed across seals 40 to formed the
inflated bags 50. The
web 10 of inflatable bags can be inflated and sealed in a wide variety of
different ways. For
example, the web 10 can be inflated and sealed in the any one of the manners
disclosed by US
Patent Nos. 8,357,439, 8,038,348, or 7,513,090, each of which are incorporated
herein by
reference in their entirety. As can be seen from Figure 3, the panels 18 of
the inflated bag 50 are
connected (either by sealing or folding) at the bottom of the pouch. Each
panel 18 has a first ply
17 and a second ply 19. As can be seen from Figure 4, the panels 18 are sealed
together at the
side edges 14 to close the inflated pouch 50. Each inflatable bag 50 has an
opening 42, and each
panel 18 of each inflatable bag 50 has connectors 22. A product may be placed
into the
inflatable bags through opening 42, and the inflatable bag 50 may be closed
using connectors 22.
[076] The web of inflatable bags 12 may be made from plastic film. An
exemplary
method for making the web 10 of inflatable bags 12 is illustrated in Figure 5.
At a first position
510, two single layers of material are placed on top of one another. The
single layers may be
plastic and, as shown, have a width W1. An exemplary width may be 20 inches,
but any width
may be used to accommodate a desired pouch width. The two layers may be of any
of the web
materials identified in any of the patents and published applications which
are incorporated
herein by reference. One or both of the layers may include an inflation edge
line of perforations
511 that is spaced apart from the edge 513. The perforations 513 are useable
to separate the
preformed bags 12 after final assembly. Alternatively, the inflation edge line
of perforations
could be in line with the edge 513 or omitted. Also at position 510, the two
layers are sealed
together according to the seal and inflation pattern 512. In the example
illustrated by Figure 5,
the seal pattern having a hexagon cell pattern and shown in Figure 1 is used.
The layers are also
sealed together at top and bottom ends as indicated by arrows 514, 516,
respectively. A
registration perforation 552 is used for registering the two labels prior to a
folding operation. In
another exemplary embodiment, the illustrated single layer of inflatable
material formed at
position 510 is replaced with material formed in accordance with US Patent No.
6,423,166.
[077] At position 520, the material formed at position 510 (or material
formed as
described in US Patent No. 6,423,166) is folded approximately in half on a
fold line 551 to form
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a bottom edge 20 of the bag 12. Cross seals 522 are formed through the four
layers (two layers
from the top set of layers and two layers from the bottom set of layers) to
form the bags 12. Also
at position 520, a trim line 553, for example, by hot knife, is added to
remove excess material.
[078] The web may be inflated at the next portion 530 to create a web of
inflated
bags 50. A line of perforations 554 may be added at station 540 or any of the
previous stations
510, 520, 530 to allow for separation after final inflation and sealing of the
bags. Typically, the
web 10 of inflatable bags 12 may be shipped to a site where items are packaged
instead of
inflating the bags at stations 530 or 540. At that site, the web 10 may be
inflated after packaging
of the product to form inflated bags 50. In the practice of the invention, the
inflated bag 12 may
alternatively be loaded with a product after the inflation and sealing that
maintains inflation. The
top of the pouch may be sealed after any product is loaded. Following position
530, position 540
represents a different location where the web 10 is inflated and sealed to
maintain the inflation of
the bags 12. The web 10 of inflatable bags 12 is packaging, for example,
rolled up or folded into
a box and shipped to the location where the bags are inflated and sealed. For
example, the web
can be inflated and sealed to maintain inflation of the pouches in any one of
the manners
disclosed by US Patent Nos. 8,357,439, 8,038,348, 7,513,090 and Published
Application No.
2009/029342.
[079] Another exemplary embodiment of a packaging web is shown in Figures
6a
and 6b. The embodiment illustrated is similar to the embodiment illustrated by
Figures 1 and 2.
As illustrated, a separate outer skin is not used. In Figure 6a, the
inflatable packaging web 700
has been formed by two layers, an outside layer 712 and an inside layer 714,
to form an opening
710. The inside layer has a pattern of inflated cells 720 formed by a
inflation process, as
discussed herein. The outside layer 712 is relatively smooth and unaffected by
the inflation
process.
[080] In Figure 6b, the seals 40 are closed to maintain the inflation in
the pouch. As
discussed herein, the panels may be made from the web disclosed in US Patent
No. D596,031 or
the web disclosed in US Patent No. 6,423,166, each of which are incorporated
herein by
reference in their entirety.
[081] Another exemplary embodiment of a packaging web is shown in Figures
6C
and 6C. The embodiment illustrated is similar to the embodiment illustrated by
Figures and 6a
and 6b, except the option of having inflation channels on both sides of the
bag is illustrated. In
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Figure 6D, the seals 40 on both sides of the bag are closed to maintain the
inflation in the pouch.
[082] In Figure 7, only a single pouch of the packaging web 700 is shown.
The
pouch 730 is defined in part by side edges 724. As discussed, the outside
layer 712 is relatively
smooth and unaffected by the inflation process. The outside layer 712 includes
imprinted
information on the relatively smooth surface, such as for example, bar code
date 654 and
packaging indicia 652.
[083] In an embodiment, the web may include an outer skin separate from the
inflation layers. The outer skin may be made of any thin material of suitable
strength, such as for
example, paper or plastic, and the material may be printable. The outer skin
remains sufficiently
smooth after all manufacturing steps, such as for example, initial inflation,
flattening, and re-
inflation, so that the bar coding is readable by a scanner. The outer skin may
be sealed on all
four sides around the perimeter of the preformed pouch. If the end user of the
on-demand
inflatable packaging produces packaging as an end product, such as for
example, a padded mailer
envelope, the outer skin may be sealed on only three sides around the
perimeter of the envelope
to allow for depositing of a product. The open side may include user sealable
features, such as
for example, a removable strip which temporarily protects an adhesive strip.
[084] An embodiment of the invention having an outer skin will now be
discussed.
The packaging web shown in Figures 8a-llb has an outer skin 612. Figure 8a is
a top view of
inflatable packaging web 610, a sectional view of the inflatable packaging web
610 is shown
along the center of a pouch in Figure 8b, and a sectional view of the
inflatable packaging web
610 is shown along the side edge of a pouch in Figure 8c.
[085] The embodiment illustrated in Figures 8a-8c is similar to the
embodiment
illustrated by Figures 6a and 6b, except the packaging web 610 includes an
outside skin 612.
The outside skin 612 may be provided around the entire web as shown or adhered
to one or both
of the panels 18. The packaging web 610 includes a string of side connected
inflatable pouches
12 with the skin 612 disposed around the pouches 12. Each pouch 12 includes at
least one
inflatable panel 18. The inflatable panel can take a wide variety of different
forms. In
exemplary embodiments, the panels 18 are made from the web disclosed in US
Patent No.
D596,031 or the web disclosed in US Patent No. 6,423,166, each of which are
incorporated
herein by reference in their entirety. Each pouch 12 is formed by sealing a
pair of panels 18
together along a bottom edge 20 and side edges 14 or by folding a larger panel
in half along the
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bottom edge and sealing the side edges together.
[086] Referring now to Figures 8b and 8c, sectional views of the packaging
web of
Figure 8a are shown. In the illustrated embodiment, outside skin 612 is only
connected to the
panels at the side edges 14, preferably by the seals 40. This structure may be
the case when the
skin 612 is disposed completely around the pouches 12 as shown, when the skin
is connected to
one side of the web, but not to the other, or when separate skins are attached
to opposite sides of
the web 610. By attaching the skin 610 to the web along the side edges 14, the
skin will wrinkle
less when the pouches are inflated, as compared to a skin that is attached to
the entire surface(s)
of the web 610. The skin 612 attached in this manner will not wrinkle
significantly, if the web is
made from a vacuum process as disclosed in US Patent No. 6,423,166. In another
exemplary
embodiment, the skin 612 is attached, adhered, or bonded to an entire surface
or substantially all
of the surface of the panels.
[087] One (Figures 8a-8c) or both (Figures 8D-8F) of the panels 18 include
an
inflation channel 30. In the Figure 8a-8c embodiment, only one inflation
channel 30 is included
and the two panels of the pouch are in fluid communication, such that
inflation of one of the
panels inflates the other panel. For example, in the illustrated embodiment in
Figures 8a-8c,
passages 32 connect the air pockets 34 at the bottoms of the panels to one
another such that
inflation through the inflation channel 30 causes inflation of both panels. In
the Figure 8D-8F
embodiment, two inflation channels 30 are included and a seal 33 isolates the
two panels, such
that deflation of one of the panels does not deflate the other panel. For
example, in the illustrated
embodiment in Figures 8D-8F, the seal 33 blocks the passages 32 connect the
air pockets 34 at
the bottoms of the panels to one another such that inflation through the
inflation channel 30
causes inflation of both panels. The inflation channel(s) 30 may be as
described by any one or
more of US Patent Nos. 6,423,166; 8,357,439; D646,972, 8,038,348, each of
which are
incorporated herein by reference in their entirety.
[088] In the example illustrated by Figures 8D-8F, the inflation channel(s)
30 include
a line of perforations 890. The line of perforations allows the inflation
channels 30 to be broken
apart without the use of a knife and removed from an inflation nozzle. In the
example illustrated
by Figures 8D-8F, the web 10 also includes cuts 892 that extend through all of
the plies of the
web 10 (through both panels 18 and through both skins 612). These cuts 892
allow the bags to
be opened more easily and to a larger extent for filling with a product.
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[089] An exemplary inflation of the web 610 is illustrated in Figures 9-
11b.
Referring now to Figure 9, the web 10 is inflated through the inflation
channel 30. As shown in
an inflated condition, the cushioning bubble pattern of the pouches is opened
by inflation on the
inward side of the pouch. Figure 10 illustrates that one of the panels is
sealed across seals 40 to
form and seal the inflated pouches 50 inside the skin 612. The inflatable web
of pouches 610
can be inflated and sealed in a wide variety of different ways. For example,
the web 10 can be
inflated and sealed in any one of the manners disclosed by US Patent Nos.
8,357,439, 8,038,348,
7,513,090 and Published Application No. 2009/029342.
[090] Another exemplary inflation of a web 610 is illustrated in Figures 9A
and 10A.
In this embodiment, the web 10 is inflated through two inflation channels 30
as shown, or
through a single inflation channel 10. As shown in an inflated condition, the
cushioning bubble
pattern of the pouches is opened by inflation on the inward side of the pouch.
The arrows 1000
in Figure 10 illustrates that a single seal is formed across the inflated
pouches 50 and the skins
612 to both seal the inflated pouches 50 and close the skins 612. This single
seal can be
accomplished in a wide variety of different ways. For example, the web 10 can
be inflated and
sealed in any one of the manners disclosed by US Patent Nos. 8,357,439,
8,038,348, 7,513,090
and Published Application No. 2009/029342.
[091] Referring to Figure 11a, in one exemplary embodiment, the skin 612 is
longer
on one side of the pouch to form a sealing flap 614. The inflated pouch 50 may
be loaded with a
product, either by a packer or a consumer, the sealing flap 614 is moved to a
closed position on
an opposing side of the pouch, and the sealing flap 614 is positioned to seal
the package at an
overlap position 616. Other sealing structure for the outer skin may be used
in the practice of
this invention, such as for example, two flaps on each side of the pouch of
equal length that are
joined together, such as for example, by a strip of adhesive on an inward side
of at least one flap.
[092] The front view of one package of the web of Figure 11 a is shown in
Figure
11b. The package 650 includes an outer skin 612 and the sealing flap 614,
which is positioned to
seal the package at an overlap position 616. Bar code data 654 and product
indicia 652 are
imprinted onto the outer skin 612. The imprinted operation may take place
before or after
inflation of the web, and before or after depositing of product by a packer.
[093] Another exemplary embodiment of a packaging web is illustrated in
Figures
12-20. The exemplary packaging web is similar to the embodiment illustrated by
Figures 6-8,
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except the outer skin is sealed to close the pouch before final inflation of
the web. The web may
be at least partially inflated before the outer skin is sealed. If so, the web
may be partially
flattened prior to sealing the outer skin.
[094] In the embodiment illustrated in Figures 12-14, a top edge of the
skin 610 is
connected to form an enclosed channel 1212, as shown in Figures 13 and 14. In
Figure 13, the
inflatable packaging web 1210 is shown along the middle of a pouch. In Figure
14, the inflatable
packaging web 1210 is shown along the edge line 14 of the pouch. In a non-
inflated and stored
configuration, the entire web may be at least partially flatten.
[095] Depositing a product in the preformed pouches of the web will now be
discussed. In the practice of this invention, a product may be deposited into
the pouch by several
different ways. For example, the product may be inserted into the open end of
the pouch, either
by manual or by automated techniques. The product can be inserted into the
open end before the
pouch is inflated and sealed. Alternatively, the product can be inserted into
the pouch through
the open end and the pouch is inflated and sealed. A packer may select one of
these options, in
view of the product size, weight, or other characteristics.
[096] The exemplary skin configuration of Figures 12-14 allows the
packaging web
1210 to be opened, loaded, closed and sealed by a packaging machine, such as
the packaging
machine 1210 illustrated in Figures 21a and 21b. Examples of packaging
machines that can be
modified, or combined, to open, load, close, and seal the outer skin are
described in US Patent
Nos. 7,552,571; 6,170,238; 6,055,796; 5,996,319; 5,987,856; and 5,944,424, and
US Publication
No. 2012/0214658, each of which are incorporated herein by reference in their
entirety. Other
skin configurations may be used in the practice of this invention to load,
close and seal a padded
package by a packaging machine.
[097] In one exemplary embodiment, a bagging machine is used to load, close
and
seal a padded package by a packaging machine. In this example, the pouch is
loaded with a
product, and the outer skin is sealed. For example, the pouch, loaded with a
product, may be
placed in a mailing bag. In one exemplary embodiment, a pouch loaded with a
product is placed
in a bag and the bag is sealed with a bagging machine. For example, a pouch
loaded with a
product may be bagged using any one of the machines disclosed by US Patent No.
8,3076,617;
7,7552,257; 6,948,296; 6,742,317; 6,543,201; 6,055,796; 5996,319; 5,987,856;
5,944,424 and
6,170,238, each of which are incorporated herein by reference in their
entirety.
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[098] Another exemplary method of using an inflated packaging web to
package a
product will now be discussed. Figures 15-20 illustrate a method of forming an
inflated/padded
package 1500 from the web 1210 with the packaging machine. Referring to Figure
15, a top of
the skin 610 is cut, slit, or otherwise separated. The machine makes the slit,
cut, or other
separation in the same manner as is disclosed in US Patent Nos. 7,552,571;
6,170,238;
6,055,796; 5,996,319; 5,987,856; or 5,944,424. Referring to Figure 16, top
lips 1610 are formed
and grabbed by belts 1612. The belts travel the same direction as the web and
act to pull the web
in the forward direction through the machinery. The belts 1612 may have the
same form
disclosed by US Patent Nos. 7,552,571; 6,170,238; 6,055,796; 5,996,319;
5,987,856; or
5,944,424. Referring to Figure 17, the belts 1612 pull the lips apart to open
the pouch. A
product 1710 is deposited into the pouch. The depositing of the product may be
done by
automated machinery or manually by hand.
[099] Figures 18-20 illustrate an exemplary process for finishing the
packaging of a
product. Figure 19 is a sectional view showing the web 610 being inflated
around a product
1710. The web may be inflated by a inflation nozzle 1810 into a inflation
channel 30. After
inflation, the web may be sealed by sealing the web at the seals 40 to
maintain the inflation.
Figure 20 illustrates the flaps 1610 of the outer skin in a sealed position.
Once the web 610
reaches this condition, the individual packages may be separated from the web,
such as for
example, by separating at edge perforations.
[0100] Referring to an exemplary embodiment illustrated in Figures 21a
and 21b, the
packaging machine 2110 includes several stations. Each station performs one or
more particular
purposes as the web travels through each station. For example, the packaging
machine 2110
includes a load station 2112, an inflation and sealing station 2114, and a
skin sealing station
2116. It will be apparent to one skilled in the art that packaging machine
2110 is offered for
exemplary purposes only, and that the invention may be practiced with other
packaging
machines, or with a combination of packaging machines and one or more manual
assembly steps.
[0101] Referring to Figures 21a, a packaging web 1210 is moved along a
path of
travel toward a load station 2112. The load station is used to deposit
automatically one of more
pieces of product into each pouch of the web 1210. At the beginning of the
load station, or
upstream from it, the enclosed channel 1212 (see Figures 13-15) is cut open.
At a separation
point 2220, the flaps 1610 are engaged and pulled apart by belts, which also
pull the web through
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the machinery. The outsides of the web travels outward along an angled path
2202 prior to a
loading point. The load station 2112 may correspond to a load station
disclosed in US Patent
Nos. 7,552,571; 6,170,238; 6,055,796; 5,996,319; 5,987,856; or 5,944,424.
[0102] The load station 2112 includes a length of travel in which the
two panels are
held apart a distance. In the length of travel, a loading cavity 2204 is
created in between the
panels of each pouch. As shown in Figures 21a and 21b, the product 1710 is
deposited a
direction D1 into the loading cavity by load station 2112. As discussed
herein, the loading may
be by automated machinery or by a manual step. At the end of the loading
station 2012, the
sides of the panel are brought back together to be contiguous or relatively
contiguous at a pre-
sealing point 2206.
[0103] The web travels on to the next station to be inflated and sealed.
In an
exemplary embodiment, inflation and sealing components 2114 correspond to
inflation and
sealing components disclosed by US Patent Nos. 8,357,439, 8,038,348, 7,513,090
or Published
Application No. 2009/029342 and are provided after the load station 2112. The
web includes a
channel for the pouches to be inflated. Referring specifically to Figures 18
and 21, the channel
30 is routed onto a pin which includes an inflation nozzle 1810. The pin and
inflation nozzle
1810 slides into the channel as the web travels through the machinery and
inflates the pouch
around the product by a blower 2208. As shown in Figure 19, the pouch is then
sealed along the
seals 40 to maintain inflation of the pouch. This sealing may be performed by
sealing belts that
have the configuration of sealing belts disclosed by US Patent Nos. 7,552,571;
6,170,238;
6,055,796; 5,996,319; 5,987,856; or 5,944,424. In one exemplary embodiment,
the pouches of
the web are vacuum formed, such as for example, by using the material
disclosed by US Patent
No. 6,423,166.
[0104] In the illustrated embodiment, a skin sealing station 2116 is
positioned after the
inflation and sealing components 2114. Still referring to Figure 21a and 21b,
the outer skin is
sealed by sealing belts. The sealing is controlled by a heater temperature
control 2210 and a
heater position control 2212. The sealing belts may have the configuration of
the sealing belts of
US Patent Nos. 7,552,571; 6,170,238; 6,055,796; 5,996,319; 5,987,856; or
5,944,424.
[0105] In another exemplary embodiment, the sealing of the pouches and
the sealing
of the skins is accomplished with a single seal. For example, after inflation
of the pouches a
single sealer would seal across all four layers, i.e., the two layers at the
end of the pouch and two
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layers of the skins 1610, at the same time. In one exemplary embodiment, the
skin sealing
station 2116 corresponds to a closure and sealing station disclosed by US
Patent Nos. 7,552,571;
6,170,238; 6,055,796; 5,996,319; 5,987,856; or 5,944,424.
[0106] A machine and method for producing inflatable material is
illustrated in Figure
22. The method is useable for forming re-inflatable material that can be used
to product
cushioning material in any of the embodiments disclosed by this application.
As discussed, the
web of preformed pouches may be of a variety of forms in the practice of the
invention. The
web may be an inflatable cushioning material designed to be inflated at a
later time by an end
user. An exemplary material is described in US Patent No. 6,423,166. The end
user inflates this
material on-demand and inflates only the amount of wrapping material that is
required at that
time.
[0107] Still referring to Figure 22, a machine 800 is arranged to
produce an inflatable
cushioning material. The machine includes two adjacent wheels, a base wheel
712 rotating in a
direction T1 and a forming wheel 710 rotating in an opposite direction T2. Two
individual layers
of plastic film 700, 702 are pulled in a direction A2 between the two wheels
710, 712. The
forming wheel 710 has a patterned surface 714 to produce an inflatable pattern
on the web 704.
The base wheel 712 may have a smooth surface 716. The inflatable cushioning
material may be
stored in bulk amounts in a container 720 in non-inflated form until an end-
user is ready to use
the material. Another machine or series of machine can attached the outer skin
and inflate the
cushioning material in an amount desired.
[0108] A top view of the web 704 of inflatable cushioning material is
shown in Figure
23. The web includes an inflation pattern 750 which includes a repetitive of
individual cells 752
arranged in an alternating pattern. After an inflation process, such as by
vacuum, the cells may
have a distinguishable shape, such as for example, hexagonal. The patterned
web may shrink in
both longitudinal and lateral directions to form the inflated pattern. Any
separate outer skin may
be attached to the inflatable cushioning material at the edges only to
minimize shrinkage or
distortion.
[0109] Figures 24a-24e illustrate an exemplary method of using a web of
inflatable
bags 12 and non-inflatable bags 2404 to make packages 2400. Figure 24a shows
an inflatable
bag 12 in a non-inflated condition. The inflatable bag 12 may have any of the
configurations
disclosed herein. In an exemplary embodiment, the inflatable bags do not have
an outer skin. In
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the illustrated embodiment, the inflatable bag 12 has two panels 18, a bottom
edge 20, and
optional connection 22. Each panel has a first ply 17 and a second ply 19 that
are sealed to form
an inflation pattern. Figure 24b shows the inflatable bag 12 after it has been
inflated and sealed,
thereby forming inflated bag 50. Figure 24c illustrates the inflated bag 50 of
Figure 24b after a
product 2402 is deposited in inflated bag 50. Figure 24d shows the inflated
bag 50 and product
2402 loaded into non-inflatable bag 2404, thereby forming the package 2400.
Inflated bag 50
may be closed by forming the optional connection 22. The optional connection
22 can take a
wide variety of different forms, examples include, but are not limited to
adhesive, a heat seal, zip
lock, tape or the like. Figure 24e illustrates the package 2400 after non-
inflatable bag 2404 is
closed with inflated bag 50 and product 2402 within the closed non-inflatable
bag 2404.
[0110] Figure 25a-25e illustrate another exemplary method of using a web
of
inflatable bags 12 and non-inflatable bags 2404 to make packages 2400. Figure
25a shows an
inflatable bag 12 in a non-inflated condition. The inflatable bag 12 may have
any of the
configurations disclosed herein. In an exemplary embodiment, the inflatable
bags 12 do not have
an outer skin. In the illustrated embodiment, the inflatable bag 12 has two
panels 18, a bottom
edge 20, and connectors 22. Each panel has a first ply 17 and a second ply 19.
Figure 25b
shows the inflatable bag 12 after a product 2402 is deposited into inflatable
bag 12, which occurs
prior to inflating inflatable bag 12. Figure 25c illustrates the inflatable
bag 12 and product 2402
of Figure 25b after inflatable bag 12 is inflated and sealed, thereby forming
inflated bag 50.
Figure 25d shows inflated bag 50 and product 2402 loaded into non-inflatable
bag 2404, thereby
forming package 2400. Inflated bag 50 is optionally closed by optional
connections 22. Figure
25e illustrates package 2400 after non-inflatable bag 2404 is closed with
inflated bag 50 and
product 2402 within the closed non-inflatable bag 2404.
[0111] The above-mentioned embodiments of methods of making packages
2400 are
only exemplary. The methods shown in Figures 24a-24e and 25a-25e provide that
the inflated
bags 50 are closed by connections 22. However, it is not a requirement that
inflatable bags 50
are closed. The inflated bags 50 may be open while in package 2400, which
means that
connections 22 are not required. Also, if inflated bag 50 includes connections
22, the
connections 22 may take any form that closes inflated bag 50, such as an
adhesive, a heat seal, a
zip-lock connection, tape or the like.
[0112] The inflated bags 50 and product 2402 may be loaded into non-
inflatable bags
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2404 to form packages 2400 using a packaging machine 2600, 2700. Referring to
the exemplary
embodiment illustrated in Figure 26a, the packaging machine 2600 includes non-
inflatable bags
2404 that travel through a load station 2610 and a sealing station 2620. It
will be apparent to one
skilled in the art that packaging machine 2610 is offered for exemplary
purposes only, and that
the invention may be practiced with other packaging machines, or with a
combination of
packaging machines and one or more manual assembly steps. Referring to Figure
26a, a web of
non-inflatable bags 2404 is moved along a path of travel toward a load station
2610. At the load
station 2610, the inflated bag 50 and product 2402 is automatically or
manually deposited into
non-inflatable bag 2404. At a separation point 2612, the sides of the non-
inflatable bag 2404 are
engaged and pulled apart by belts, which also pull the web of non-inflatable
bags 2404 through
the packaging machine. The outside of the web travels outward along an angled
path 2614 prior
to a loading point 2616. The load station 2610 may correspond to a load
station disclosed in US
Patent Nos. 7,552,571; 6,170,238; 6,055,796; 5,996,319; 5,987,856; or
5,944,424.
[0113] The load station 2610 includes a length of travel, along which
the sides of the
non-inflatable bags 2404 are held apart a distance. In this length of travel,
a loading cavity 2616
is created in between the sides of each non-inflatable bag 2404. As shown in
Figure 26a, the
inflated bag 50 and product 2402 is deposited in a direction D1 into the
loading cavity 2616 of
the opened non-inflatable bag 2404 at load station 2610. As discussed herein,
the loading may
be by automated machinery or by a manual step. At the end of the loading
station 2610, the
sides of the non-inflatable bag 2404 are brought back together to be
contiguous or relatively
contiguous at a pre-sealing point 2618.
[0114] The web of non-inflatable bags 2404 loaded with inflated bags 50
and product
2402 travels on to the next station 2620 to be sealed. In an exemplary
embodiment, sealing
components 2620 correspond to the sealing components disclosed by US Patent
Nos. 8,357,439,
8,038,348, 7,513,090 or Published Application No. 2009/029342 and are provided
after the load
station 2610. As shown in Figures 24e and 25e, the non-inflatable bag 2404 is
sealed. This
sealing may be performed by sealing belts that have the configuration of
sealing belts disclosed
by US Patent Nos. 7,552,571; 6,170,238; 6,055,796; 5,996,319; 5,987,856; or
5,944,424.
[0115] Figures 27a-27c illustrates another exemplary embodiment of a
packaging
machine 2700 that may be used to load inflated bag 50 and product 2402 into
non-inflatable bag
2404. A web 2702 of non-inflatable bags 2404 is loaded into packaging machine
2700. An
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indexing mechanism 2701 moves the web 2702 along a path of travel. The
indexing mechanism
2701 may take a wide variety of different forms. For example, any indexing
mechanism that can
be controlled to index the non-inflatable bags 2404 of the web 2702 may be
used. In the
exemplary embodiment shown in Figures 27a-27c, the indexing mechanism includes
a pair of
rollers 2704 that form a nip that engages web 2702. Packaging machine 2700
also includes an
opening arrangement 2710 to create an opening 2716 in non-inflatable bag 2404.
In an
exemplary embodiment, the opening arrangement includes grippers 2712 that pull
apart the sides
of non-inflatable bag 2404. The opening arrangement 2710 may take a wide
variety of different
forms. For example, any opening arrangement that can be controlled to open the
non-inflatable
bags 2404 of web 2702 may be used. In another exemplary embodiment, a blower
(not shown)
may be used to create opening 2716. The above-mentioned embodiment for a
packaging
machine 2700 is only exemplary. The packaging machine 2700 may also have the
configuration
of any of the packaging machines disclosed by US Patent Nos. 8,307,617,
8,069,635, or
7,654,064 and US Publication Nos. 20120073246, 20100122512, or 20090064637,
each of
which are incorporated herein by reference in their entirety.
[0116] Referring to the exemplary embodiment provided in Figures 27a-
27c, the
grippers close non-inflatable bag 2404 after the inflated bag 50 and product
2402 are loaded into
the non-inflatable bag 2404. However, if the opening arrangement 2710 does not
include
grippers 2712, the non-inflatable bag 2404 may be closed in another manner.
For example, in
certain exemplary embodiments, packaging machine 2700 may close the non-
inflatable bag 2404
simply by closing the seal bar.
[0117] Still referring to the exemplary embodiment provided in Figures
27a-27c, the
non-inflatable bag 2404 is sealed using sealing arrangement 2720. The non-
inflatable bag may
be sealed at the position located in Figures 27a-27c, or the grippers 2712 may
release the non-
inflatable bag 2404, and the non-inflatable bag 2404 may be indexed to another
position for
sealing. In one exemplary embodiment, the non-inflatable bag 2404 is sealed
while the grippers
2712 is holding the non-inflatable bag 2404 closed. The sealing arrangement
2720 may take a
wide variety of different forms. For example, any mechanism that applies heat
to the non-
inflatable bag 2404 to create a seal may be implemented. In the exemplary
embodiment
provided in Figures 27a-27c, the sealing arrangement 2720 includes a seal
backing bar 2718 and
a heating element 2716 that are selectively moved into and out of engagement.
The non-
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inflatable bag 2404 is sealed by clamping the non-inflatable bag between the
seal backing bar
2718 and heating element 2716. In an exemplary embodiment, the seal backing
bar 2718 has a
rubber seal backing element 2717. The seal backing bar 2718 may be moved to
the clamped
position.
[0118] A controller (not shown) is in communication with the indexing
mechanism
2701, the opening arrangement 2710, and the sealing arrangement 2720. The
controller controls
the indexing mechanism 2701, the opening arrangement 2710, and the sealing
arrangement 2720
to convert the non-inflatable bags 2404 into packages 2400 holding inflated
bag 50 and product
2402. A wide variety of controllers can be used and programmed to control the
indexing
mechanism 2701, the opening arrangement 2710, and the sealing arrangement 2720
as described
herein. For example, the controller and controller algorithms described in
U.S. Pat. No.
5,341,625 to Kramer can be modified to control the indexing mechanism 2701,
the opening
arrangement 2710, and the sealing arrangement 2720 to form packages 2400.
[0119] Referring to Figures 27a-27c, the web 2702 of non-inflatable bags
2404 is
moved through packaging machine 2700 using indexing mechanism 2701. The
indexing
mechanism 2701 moves a non-inflatable bag 2404 of web 2702 into a position to
be opened by
opening arrangement 2710 to create opening 2716. Inflated bag 50 and product
2402 are loaded
into the opened non-inflatable bag 2404. In an exemplary embodiment, grippers
2712 are used
to create opening 2716, and grippers 2712 are used to close non-inflatable bag
2404. Once the
non-inflatable bag is closed, sealing arrangement seals the non-inflatable bag
to create package
2400.
[0120] Figures 28A- 28E are similar to Figures 24A-24e, except the
panels of the web
of inflatable bags 12 are separately inflatable and are optionally isolated
from one another, so
that if one panel deflates, the other panel remains inflated. Figure 28A shows
an inflatable bag 12
in a non-inflated condition. The inflatable bag 12 may have any of the
configurations disclosed
herein. In an exemplary embodiment, the inflatable bags do not have an outer
skin. In the
illustrated embodiment, the inflatable bag 12 has two panels 18, a bottom edge
20, and optional
connection 22. Each panel has a first ply 17 and a second ply 19 that are
sealed to form an
inflation pattern. Figure 28B shows the inflatable bag 12 after it has been
inflated and sealed,
thereby forming inflated bag 50. Figure 28C illustrates the inflated bag 50 of
Figure 28B after a
product 2402 is deposited in inflated bag 50. Figure 28D shows the inflated
bag 50 and product
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2402 loaded into non-inflatable bag 2404, thereby forming the package 2400.
Inflated bag 50
may be closed by forming the optional connection 22. The optional connection
22 can take a
wide variety of different forms, examples include, but are not limited to
adhesive, a heat seal, zip
lock, tape or the like. Figure 28E illustrates the package 2400 after non-
inflatable bag 2404 is
closed with inflated bag 50 and product 2402 within the closed non-inflatable
bag 2404.
[0121] Figures 29A- 29E are similar to Figures 25A-25e, except the
panels of the web
of inflatable bags 12 are separately inflatable and are optionally isolated
from one another, so
that if one panel deflates, the other panel remains inflated. Figure 29A shows
an inflatable bag
12 in a non-inflated condition. The inflatable bag 12 may have any of the
configurations
disclosed herein. In an exemplary embodiment, the inflatable bags 12 do not
have an outer skin.
In the illustrated embodiment, the inflatable bag 12 has two panels 18, a
bottom edge 20, and
connectors 22. Each panel has a first ply 17 and a second ply 19. Figure 29B
shows the
inflatable bag 12 after a product 2402 is deposited into inflatable bag 12,
which occurs prior to
inflating inflatable bag 12. Figure 29C illustrates the inflatable bag 12 and
product 2402 of
Figure 25b after inflatable bag 12 is inflated and sealed, thereby forming
inflated bag 50. Figure
29D shows inflated bag 50 and product 2402 loaded into non-inflatable bag
2404, thereby
forming package 2400. Inflated bag 50 is optionally closed by optional
connections 22. Figure
29E illustrates package 2400 after non-inflatable bag 2404 is closed with
inflated bag 50 and
product 2402 within the closed non-inflatable bag 2404.
[0122] The above-mentioned embodiments of methods of making packages
2400 are
only exemplary. The methods shown in Figures 28A-28E and 29A-29E provide that
the inflated
bags 50 are closed by connections 22. However, it is not a requirement that
inflatable bags 50
are closed. The inflated bags 50 may be open while in package 2400, which
means that
connections 22 are not required. Also, if inflated bag 50 includes connections
22, the
connections 22 may take any form that closes inflated bag 50, such as an
adhesive, a heat seal, a
zip-lock connection, tape or the like.
[0123] While various inventive aspects, concepts and features of the
general inventive
concepts are described and illustrated herein in the context of various
exemplary embodiments,
these various aspects, concepts and features may be used in many alternative
embodiments,
either individually or in various combinations and sub-combinations thereof.
Unless expressly
excluded herein all such combinations and sub-combinations are intended to be
within the scope
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of the general inventive concepts. Still further, while various alternative
embodiments as to the
various aspects, concepts and features of the inventions (such as alternative
materials, structures,
configurations, methods, circuits, devices and components, alternatives as to
form, fit and
function, and so on) may be described herein, such descriptions are not
intended to be a complete
or exhaustive list of available alternative embodiments, whether presently
known or later
developed. Those skilled in the art may readily adopt one or more of the
inventive aspects,
concepts or features into additional embodiments and uses within the scope of
the general
inventive concepts even if such embodiments are not expressly disclosed
herein. Additionally,
even though some features, concepts or aspects of the inventions may be
described herein as
being a preferred arrangement or method, such description is not intended to
suggest that such
feature is required or necessary unless expressly so stated. Still further,
exemplary or
representative values and ranges may be included to assist in understanding
the present
disclosure; however, such values and ranges are not to be construed in a
limiting sense and are
intended to be critical values or ranges only if so expressly stated.
Moreover, while various
aspects, features and concepts may be expressly identified herein as being
inventive or forming
part of an invention, such identification is not intended to be exclusive, but
rather there may be
inventive aspects, concepts and features that are fully described herein
without being expressly
identified as such or as part of a specific invention. Descriptions of
exemplary methods or
processes are not limited to inclusion of all steps as being required in all
cases, nor is the order
that the steps are presented to be construed as required or necessary unless
expressly so stated.
