Abstract:
A transfer and dispensing apparatus is disclosed for the conveying and separation of packaging material, cushions or pillows when needed by the operator. When a packer working over a conveyor receives a box that requires void fill, an operating switch such as a foot pedal is depressed to dispense pillows from the apparatus and into the box in a connected strip. When the operating switch is released, the apparatus stops dispensing pillows, separates the continuous strip of pillows along a transverse perforation in the strip, and ejects the end of the separated segment. The packer can then complete packing the box by placing the severed end of the pillows into the box, advance to the next box, and repeat the process. The transfer and dispensing apparatus may be positioned in any convenient location including adjacent to, above or attached to the inflation device.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. Non Provisional Application No. 11/867,452, filed on Oct. 4, 2007, now U.S. Pat. No. 8,240,533, issued Aug. 14, 2014, which claims the benefit of U.S. Provisional Application No. 60/849,537, filed on Oct. 4, 2006, U.S. Provisional Application No. 60/856,528, filed Nov. 20, 2006, and U.S. Provisional Application No. 60/875,063, filed on Dec. 15, 2006. The content of each of these applications is hereby incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to packaging materials and more particularly is directed to systems and methods used in the manufacturing and utilization of packaging pillows. 
     BACKGROUND OF THE INVENTION 
     Many techniques have been used to pack items for shipping and to absorb impacts on goods that are packed for shipping. Popular shipping protection methods includes the use of foam “peanuts,” molded foam components, formed paper, and molded pulp packaging components. 
     A technique that has gained recent popularity involves the use of air-inflated cushions formed from a film material (“pillows”), such as disclosed in U.S. Pat. No. 6,932,134and pending Application No. 11/185,927, now U.S. Pat. No. 7,578,333, issued Aug. 25, 2009. This style of packaging allows low-volume, uninflated pillow film materials to be shipped to packers, who then inflate the pillows as needed into shock-absorbing packing material. Pillow inflating machines may be used at the point of packaging to provide fully formed pillows at the time of packaging, thereby eliminating the need to store bulky packaging materials at the packaging site. The inflated pillows are formed in a continuous strip of individual pillows, and the desired length or number of the inflated pillows are separated from the continuous strip of inflated pillows as they are dispensed from the pillow inflating machine. 
     Air inflating machine systems may produce the air-inflated pillows at a rate that differs from the rate at which the actual packaging of goods is occurring. To accommodate the differences in the rate of pillow inflation and packaging use, the strip of formed packaging material is often fed into a holding bin adjacent to the inflation device. When packing material is needed by the packer, the end of the continuous strip of inflated pillows is withdrawn from the holding bin, an appropriate length of inflated pillows is measured by the packer, separated from the continuous strip and then placed into a shipping box to protect the packaged goods. 
     When a packer is using the pillows as packaging material, he must pull the required material out of the holding bin, typically using both hands to pull and place a number of pillows into the shipping box to fill any voids that may be present. When a sufficient number of pillows have been placed in the box to fill the voids, the packer must separate the pillows from the continuous strip of pillows. The need for the packer to reach into the holding bin and manually separate the required length or number of inflated pillows can be a time-consuming and laborious process, decreasing the overall efficiency of the packaging operation and thereby increasing costs. In some applications, a transfer stand may be placed in front of the holding bin with the end of the continuous strip of pillows draped over the transfer stand so that the packer does not have reach into the holding bin every time additional pillows are required. However, this still requires the packer to manually pull and tear the required number of pillows for packaging. A device is needed that can facilitate and improve the efficiency of dispensing air-inflated pillows to aid the packer in the packaging operation. 
     SUMMARY OF THE INVENTION 
     According to one embodiment of the present invention, a transfer and dispensing apparatus conveys and separates packaging material, cushions or pillows when needed by the operator. When a packer working over a conveyor receives a shipping box that requires void fill, an operating switch such as a foot pedal is depressed to dispense pillows from the apparatus and into the box in a connected strip. When the operating switch is released, the apparatus stops dispensing pillows, separates the continuous strip of pillows along a transverse perforation in the strip, and ejects the end of the separated segment. The packer can then complete packing the box by placing the severed end of the pillows into the box, advance to the next box, and repeat the process. The transfer and dispensing apparatus may be positioned in any convenient location including adjacent to, above or attached to the inflation device. 
     The invention relates to a packing material transfer apparatus. A preferred embodiment of the transfer apparatus includes a plurality of traction members, such as grippers, that are configured for gripping a chain of pre-inflated pillows, which are connected to each other end to end. A driving mechanism is operably associated with the traction members to drive the traction members for drawing the chain from an input location to an output location, in which the pillows are dispensed. Additionally, a motor is configured for powering the driving mechanism. The preferred traction members are spaced at a pre-determined distance from each other, which distance corresponds to the position of recessed zones along the chain, for example, zones between the inflated pillows, such that the traction members are received within the recessed zones to engage and move the chain. 
     A guide surface can be provided, which is configured for guiding the pillows therealong, and the driving mechanism can be configured for moving the traction members along a path adjacent to the guide surface for trapping the pillows therebetween. The guide surface can be stationary or movable and can be arcuate or have another suitable shape. The driving mechanism can include a drum to which the traction members are mounted to drive the traction members along a curved, and preferably circular path, such as when using an arcuate guide surface. 
     The guide surface is preferably driven for moving the chain cooperatively with the traction members. In one embodiment, the guide surface and traction members include rollers or driven belts, preferably extending on opposite sides of a longitudinal axis of the chain, and which can be arranged as conveyers. 
     The preferred transfer apparatus preferably includes a detachment mechanism that is configured for detaching at least one of the pillows from the chain. The detachment mechanism can have a detachment element that is operable to break a weakened area between the adjacent pillows and the chain to separate the pillows from each other. The detached pillows can be dispensed at the output location. In a preferred embodiment, the detachment element includes at least one cutter configured to rotate through the weakened area to separate adjacent pillows. Preferably, the cutter includes first and second cutters configured to rotate in opposite directions to cooperatively pull material of the chain of pillows around the weakened area against the cutters. 
     A pillow detector can also be provided for detecting the position of individual or groups of pillows in the chain. The detector is preferably connected for operating the detachment element to detach at least one pillow from the chain, in which this operation is activated based on the detected positions of the pillows. The pillow detector can include a follower configured and positioned to follow contours of the pillows to detect the positions thereof. In one embodiment, the pillow detector includes a vacuum source configured to detect changes in vacuum depending on the region of the chain associated therewith as the chain is moved in relation thereto, thus enabling the vacuum source to be used to determine the positions of the pillows. 
     The traction members of one embodiment include nip elements to grip the chain by nipping it. The driving mechanism can be configured to rotate the nip elements for drawing the chain towards the output location. Furthermore, the nip elements can include rollers and conveyers, for example. 
     The traction members can include forward and aft traction members, with the driving mechanism configured for operating the forward and aft traction members at different speeds, such as by stopping one and moving the other or by moving each in different directions, to detach detachment of at least one pillow from the chain. Also, the driving mechanism can be configured for operating the forward and aft traction members at different speeds to initiate a tear between the pillow or pillows to be detached and the remainder of the chain at one or both of the lateral sides of the chain, so that the tear can continue across the remainder of the area between the pillows to be detached and the remainder of the chain. In one embodiment, a pillow chain transfer system is provided, in which two or more transfer apparatuses can be disposed and associated with respect to each other for transferring the chain from the output location of one of the transfer apparatuses to the output location to another of the transfer apparatuses. 
     Consequently, the invention provides a device that facilitates and improves the efficiency in handling chains of inflated pillows, which can be used for protecting packaged articles. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an automated transfer and dispensing apparatus in use alongside other components of an air inflated packaging pillow system; 
         FIGS. 2A and 2B  are side views of another configuration of an air inflation packaging pillow system, with the automated transfer and dispensing apparatus in the lowered and raised positions, respectively; 
         FIG. 3  is a side view of another configuration of an air inflation packaging system; 
         FIG. 4  is a perspective view of a preferred embodiment of an air inflation packaging pillow system; 
         FIG. 5  is a top view thereof; 
         FIG. 6  is a cross-sectional, diagrammatic view of components of the automated transfer and dispensing apparatus at section  5 - 5  as identified in  FIG. 5 ; 
         FIGS. 7 and 8  are perspective views of components of other embodiments of automated transfer and dispensing apparatuses; 
         FIGS. 9 and 10  are side views of components of other embodiments of automated transfer and dispensing apparatuses; 
         FIGS. 11 and 12  are front and rear side perspective views of an alternative embodiment of an automated transfer and dispensing apparatus; 
         FIG. 13A  is a perspective view of a drum thereof; 
         FIG. 13B  is a perspective view of another embodiment of a drum with biasing members; 
         FIG. 14  is a rear, out-away view of a cutting mechanism of the transfer and dispensing apparatus of  FIGS. 11 and 12 ; 
         FIG. 15  is a side, cut-away view thereof; 
         FIG. 16  is a side view of another embodiment of a drum with biasing members of an automated transfer and dispensing apparatus; 
         FIG. 17  is rear view of another embodiment of a cutting mechanism; 
         FIGS. 18A and 18B  are perspective and side views of another embodiment of an automated transfer and dispensing apparatus; 
         FIG. 19  is a perspective view of one embodiment of an intake funnel; and 
         FIG. 20  is a top view of a typical web material used to form inflated pillows. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In  FIG. 1 , a preferred embodiment of the transfer and dispensing apparatus  10 , which can be configured as an air-pillow burster, is shown positioned adjacent to and above the location of a holding bin  2 . The holding bin  2  may be used to collect pillows  101  as they are inflated and sealed by a pillow inflation and sealing device  5 , for example, as disclosed in U.S. Pat. No. 6,932,134, the disclosure of which is incorporated herein by reference. Preferably, the pillows are only filled with a fluid, and more preferably a gas, such as air, and most preferably do not contain a substantial amount of solids therein. As inflated pillows  101  are formed by the pillow manufacturing devices, they fall into the holding bins in a continuous strip  100 . A sensor  6  associated with the holding bin  2 , may be used to identify the amount of inflated pillows  101  that have accumulated in the holding bin  2  or when the holding bin  2  is filled to a predetermined level, and give appropriate instructions to control the manufacture of additional pillows, such as by interrupting the making of pillows  101  by the pillow manufacturing device  5 . 
       FIG. 20 , shows a typical web or strip  610  of uninflated material to be inflated and sealed into a series of pillows attached at perforated edges. The web  610  may be made of a variety of different materials, including materials such as polyethylene resins such as LDPE, LLDPE, HDPE; metallocenes; EVAs; and blends thereof. The web  610  has a top edge  612  and a bottom edge  614 , both of which are closed. The web  610  includes generally transverse seals  616  and generally transverse perforations  618 . The transverse seals  616  join a top sheet  620  of the web  610  to a bottom sheet  622  of the web  610  along the seals  616 , while the transverse perforations  618  perforate the web through the top and bottom sheets  620  and  622 . According to the embodiment shown, the transverse seals  616  begin at the bottom edge  614  of the web  610  and extend to a distance d from the top edge  612 . The web  610  has a width w, and a perforation-to-perforation length  1 , which may be altered depending on the particular type of pillow to be manufactured. 
     While inflated pillows  101  continue to accumulate in the holding bin  2 , the free end  102  of the continuous strip of inflated pillows  100  is drawn out of the holding bin  2  by the transfer and dispensing apparatus  10 , which is preferably configured to dispense the free end  102  of pillows  101  to the operator when needed. The sensor  6  on the holding bin  2  can limit the transfer of inflated pillows  101  out of the holding bin  2  when supplies are low to prevent premature tearing of the continuous strip of pillows  100 . 
       FIGS. 2A and 2B  show another preferred embodiment of the transfer and dispensing apparatus  10 , shown as part of a larger air inflation packaging pillow system.  FIG. 2A  shows a pillow inflation and sealing device  5  forming a strip of pillows  100 , which is fed into one end of the transfer and dispensing apparatus  10 . In this embodiment, the apparatus  10  is associated with, and preferably moveably mounted on, a support, such as an upright member, which is preferably a pole  3 . A drive mechanism is preferably associated with the apparatus  10  and the pole  3 , and configured for controlling movement of the apparatus  10  up and down the pole  3 . The drive mechanism can be manually driven, such as by a pulley and lever system, or the drive mechanism can be powered, such as by an electric motor  4 , and can use other systems, such as a worm gear, powered pulleys, and actuators, such as pneumatic or hydraulic. In  FIG. 2A , the apparatus  10  is shown in the lowered position with respect to the pole  3  such that the lead end of the formed strip of pillows  100  can be easily fed into the apparatus by a standing or sitting operator, the loading position preferably being between about 2 and 7 feet off the floor. 
     As shown in  FIG. 2B , the apparatus  10  is raised to a height on the pole  3  that is about at least as high as the top of a pillow holding bin  2 , which in this embodiment is positioned above a work station or assembly bench  8 . In this position, the apparatus  10  can dispense strips of pillows  100  in desired lengths for storage in the holding bin  2 . Then, as a packer works at the assembly bench  8  to pack a package, the packer merely needs to reach into the bin, such as into an opening at the bottom of the holding bin  2  that is conveniently located above the assembly bench to retrieve multiple strips of pillows  100  as desired. 
     The transfer and dispensing apparatus  10  can alternatively be placed in a position away from either the pillow manufacturing device  5 , the holding bin  2 , or both. For example, a conveyor mechanism can be used to transfer the continuous strip of inflated pillows  100  from the inflation machine  5  to a holding bin  2  located some distance away. From there, the pillows  101  can be dispensed for availability to the packer. 
     As shown in  FIG. 3 , for example, one or more of the apparatuses  10  can be positioned in a system to convey pillows  101  to a remote location from the pillow manufacturing device  5 . The transfer apparatus  10  in  FIG. 3  is associated with an inflation and sealing device  5  for forming the strip of pillows  100 , and a conveyor mechanism that preferably includes a pneumatic duct or conveyer shaft  11 , a pillow transport mechanism such as a blower  7 , and a controller  9 , which are preferably configured to transport strips of pillows to various remotely located holding bins  2 . The shaft  11  preferably extends to a height at least above the top of the holding bins  2  for dispensing the strip of pillows  100  therein, preferably leaving sufficient height thereunder for operators to walk pass. Positioning the shaft  11  at this elevated height advantageously allows the shaft to be clear of the working area below, which can be used for another processes or as a throughway for packages, machinery or people. The conveyer preferably provides at least about  6 . 5  feet for operators to walk thereunder, although more or less can alternatively be provided, such as in embodiments in which it is not desired to provide a walkway thereunder. At least one diverter  13  is associated with the shaft  11 , preferably adjacent to a holding bin  2 , and configured for diverting a strip of pillows from the shaft  11  into the holding bin  2 . 
     In this configuration, the system can transport desired lengths of pillow strips  100  to remote holding bins  2  for storage therein. For example, the apparatus  10  can deliver a strip of pillows  10  into the shaft  11 , for example through shaft opening  12 , and the controller  9  can control the blower  7  to transport the strip  100  through the shaft. The controller  9  also preferably controls the diverters  13  to determine to which holding bin the strip of pillows is delivered, and the diverters are configured to direct the pillows conveyed through the shaft into the selected bin. Thus, the system can maintain and refill the amount of pillows strips  100  that are contained in multiple holding bins located remotely from the transfer and dispensing apparatus  10  and inflation and sealing device  5 . An alternative embodiment employs other types of conveyers, for example using conveyer belts to move the pillows. 
     As shown in  FIGS. 4 and 5 , the preferred embodiment of the transfer and dispensing apparatus  10  includes first and second motor support mounts  110 , 111  arranged on opposite sides of a pillow support and guide saddle  112 . The motor support mounts  110 , 111  hold one or more motors, and preferably two motors  113 , 114  and  115 , 116  each, with each motor connected to and driving a pillow engagement or traction member, such as a pair of nip rollers  117 , 118 . The nip rollers  117 , 118  are configured to grip the edge of the pillows  101  in order to move and manipulate the continuous strip of pillow material  100  as it is drawn through the apparatus  10  and dispensed to the user. Each nip roller  117 , 118  can be driven directly by a motor  113 - 116 , or can be driven through a gearing mechanism. Other configurations for driving the nip rollers are well known and within the knowledge of those of skill in the art. 
     An infeed/intake/inlet section  121  (shown in  FIG. 5 ) of the apparatus  10  is located adjacent to the feed nip rollers  117 , 118  and is tapered or flared to provide a smooth transition section from the holding bin  2 . The taper of the infeed section  121  allows the continuous strip of pillows  101  to be drawn from the holding bin  2  without catching, breaking or tearing, for example. The infeed section  121  is adjustable in both height and width to allow for pillows of differing inflated thickness and width. As it is drawn through the apparatus  10 , the continuous strip of inflated pillows  100  may rest on or be guided by the pillow support saddle  112 . The support saddle  112  may be arcuately shaped to match the contour of the continuous strip of pillows  100  as it is drawn from the holding bin  2 . An edge guide plate  126  defines a path for the edges of the pillows  101  through the apparatus  10 , and may be supported by the motor support mount  110 , 111  in a position between the feed nip rollers  117 , 118  and the dispensing nip rollers  119 , 120 . 
     The motors  113 - 116  operate at variable speeds and directions, and are controlled by a motor controller  20 . The motor controller  20  controls the speed and direction of rotation of each of the motors  113 - 116 . The motor controller  20  may receive instructions from the user via an operating switch, such as a foot pedal  21 . The motor controller  20  may also receive instructions from other components of the system. For example, the above disclosed sensor  6  mounted on the holding bin  2  could instruct the motor controller  20  to stop the apparatus  10  from withdrawing pillows  101  from the holding bin  2  when the number of inflated pillows  101  is low. 
     Depending upon the desired function, the motor controller  20  coordinates the motors so that they work in unison to drive the pairs of nip rollers  117 - 120  in a way to manipulate the movement of pillows  101  in a desired manner. For example, the nip rollers  117 - 120  can be driven in unison so that the continuous strip of pillows  100  is drawn from the holding bin  2 , transferred through the apparatus  10 , and dispensed directly to the user in a continuous, steady rate for as long as the foot pedal  21  is depressed. Then, when the desired number of pillows  101  have been dispensed, the operator releases the foot pedal  21  and the nip rollers  117 - 120  are driven in a manner so that the feed nip rollers  117 , 118  rotate in one direction while the dispensing nip rollers  119 , 120  rotate in the opposite direction sous to pull the strip of pillows  100  apart and thus separate a desired length or number of pillows  101  from the continuous length of pillows  100 . Once separated, the dispensing nip rollers  119 , 120  can dispense the separated segment of pillow packaging material to the user. The left and right feed and/or dispensing rollers can also move at different speeds to initiate a tear on one side. Also, the infeed rollers  117 , 118  can move in reverse to help tear the chain of pillows  101 . 
     In the operation of the preferred embodiment, as the segment of pillows  101  is separated from the continuous strip  100  and dispensed from the apparatus  10 , the feed nip rollers  117 , 118  maintain the position of the leading edge  102  of the remaining continuous strip of pillows  101 , and keep it from falling back into the bin  2  or out of the apparatus  10 . The feed nip rollers  117 , 118  then advance the leading edge  102  of the continuous strip  100  forward, the dispensing nip rollers  119 , 120  grip the leading edge  102  of the strip of pillows, and the apparatus  10  is again ready to dispense pillows for the packing of the next box. 
     As shown in  FIGS. 4 and 5 , the preferred embodiment of the apparatus  10  can use a follower arm  304  as the pillow position detector to identify the location of the perforation  104  between pillows  101  so that the strip  100  may be separated. The follower arm  304  is mounted on a transverse shaft  305  extending between the first and second motor support mounts  110 , 111 , and can swivel about the axis of the transverse shaft  305 . The transverse shaft  305  can be engaged to the follower arm  304  so that the shaft  305  also rotates about its longitudinal axis as the follower arm  304  swivels. A follower wheel  306  is located at the end of the follower arm  304  and is able to roll over the inflated pillows  101  and follow the contour of the pillows as they move through the apparatus  10 . As the follower wheel  306  rolls along the contour of the pillow  101 , the wheel  306  will rise along the inflated pillow portions  105  and descend into the valleys  103  at the transverse borders between the pillows  101 . A spring, such as a coil spring, can be mounted on the transverse shaft  305  to dampen unwanted oscillations in the follower arm  304  as it swivels, and to keep the follower wheel  306  pressed against the surface of the pillows. A counterweight  307  mounted on the follower arm  304 , on the end opposite the follower wheel  306 , may be used to counteract the weight of the follower wheel  306  and arm  304 , thereby keeping the follower aim  304  in balance about the transverse shaft  305 . 
     A sensor  310  mounted at or near the end of the transverse shaft  305  may respond to rotation of the shaft to send a signal to the motor controller  20  to signal when the follower wheel  306  is located in one of the valleys  103  between pillows  101 . Upon receiving the signal, the motor controller  20  can stop the dispensing of pillows  101 . Thus, when the operator releases the foot pedal  21  or otherwise indicates that sufficient pillows have been dispensed, the driving mechanism stops the strip of pillows  100  at the location of the perforation  104  between the pillows, allowing the segment of pillows to be separated by the driving mechanism or one of the other identified separation mechanisms. 
     As shown in  FIG. 6 , the nip rollers can be adjusted in relation to one another, such as in horizontal and vertical directions “a” and “b,” for example, to accommodate for differences in height and width of the pillow film material, and for feeding material into the apparatus  10 . The nip rollers can also be positioned and spaced to squeeze the lateral sides  101   a ,  101   b  of inflated portion of the pillows  101  in a manner so as to fully pressurize or increase the pressurization of at least the center section of the inflated pillow  101  as it is drawn through the apparatus  10 . As further discussed below, this increases the height and rigidity of the pillows, and can ensure that at least the center section  105  of the pillow  101  is fully formed, which is useful for purposes of identifying the position of individual pillows  101  as the continuous strip of pillows  100  is being drawn through the apparatus  10 . 
     Typically, and for a variety of reasons, during the inflation of the pillows  101 , the film material is not fully inflated. In one embodiment, as the follower wheel  306  presses down on the pillows  101 , the wheel  306  displaces all of the air inside the pillow off to the side of the wheel  306  by providing a stiffer bias of wheel against the pillows. In one embodiment, a wheel is fixed so it does not rise and fall along the contour of the inflated pillow, for example, but this would prevent the follower wheel from locating the spaces or perforation between the pillows. Having the inflated pillows  101  squeezed by the nip rollers as described above can assist in keeping the contour of the pillows fully defined to provide a distinct height differential between the location of the pillows and the transverse border between the pillows where the film material may be perforated. 
     In other embodiments of the invention, other types of traction members, such as other types of rollers, wheels or drive belts, can be used to grip and move the continuous strip of pillows. In another embodiment shown in  FIG. 7 , top drive belts  201  and bottom drive belts  202  cooperate to move and manipulate the pillows  101 . The bottom drive belts  202  may be fixed in position while the top drive belts  201  can be adjustable to accept pillows  101  of differing heights. Together, the top and bottom belts  201 , 202  squeeze the pillows  101  to grip them and rotate to move them. The drive belts  201 , 202  can also move independently of each other in order to manipulate the pillows  101  as desired. For example, as shown in  FIG. 8 , the apparatus may have four bottom belts  202  and four top belts  201 , generally positioned to engage the corners or quadrants of a pillow  101 , and can move in unison to drive the strip of pillows  100  forward. The belts  201 , 202  can also move differentially to apply a tearing force to just one edge of the strip of pillows  100  or hold the strip of pillows in position while a segment of pillows  101  is separated and dispensed from the apparatus  10 . 
     Other mechanisms can also be incorporated into the apparatus to draw the continuous strip of pillows  100  from the holding bin  2  and move it through the device  10 . In one embodiment, a ducted conveyor (not shown) that uses forced air-flow or differential air pressure to move the strip of pillows  100  through the machine is used. The ducted conveyor includes a duct where streams of air are directed at the pillows  100  to blow them through the apparatus. Alternatively, a duct incorporating a low pressure area can also be used to draw the pillows into the apparatus. 
     In other embodiments of the invention, different numbers of motors and mechanisms for driving the nip rollers or belts can be incorporated. For example, a single motor can drive the feed rollers in unison while two or more motors are used to achieve the differential rotation required for the tearing and dispensing of a segment of pillows. In another embodiment, all of the nip rollers are driven by a single motor via a differential transmission that can independently control each nip roller. Additional motors can also be added to convey the pillow material through the apparatus, or for other functions as required. 
     In separating the segment of pillows  101  from the continuous strip of pillows  100  being drawn from the holding bin  2 , the nip rollers can be coordinated and driven in a manner so as to differentially tension one edge of the continuous strip of pillows  100  while leaving the other edge slack to start a tear at one edge of the strip of pillows at the desired location for separation, and then separate the pillow segment from the continuous strip. A locking mechanism can also be incorporated to lock one or more of the nip rollers, thereby holding an edge to achieve the same result of tearing and separating the pillows. 
     In another embodiment of the invention, a segment of the continuous strip of pillows  100  can be separated by a break bar, such as break bar  302  (shown in  FIG. 9 ) that operates on one or both of the edges of the strip, or between the edges, to start a tear at the perforation  104  located between the pillows  101 , making it easier for the drive system to pull the pillows apart or causing the tear. When the strip  100  reaches the proper position for separation, the nip rollers stop rotating and hold the material in position at the location of the break bar  302 . 
     An actuator  303  moves the break bar  302  against the strip  100  to initiate tearing of the material between the pillows  101 . The break bar  302  can have multiple points that are driven through the material at the perforation  104 . In another embodiment of the invention, separation of the strip  100  is accomplished by one or more stoppers, such as break bar  302 , that preferably move up against the film material just before the point of desired separation and clamp the material against a plate on the opposite side or block the moment of the pillows  101  behind the stopper. With the strip  100  clamped or otherwise stopped by the stoppers, the dispensing nip rollers tear off the segment of pillows, and then dispense the segment to the operator. 
     Another embodiment of the invention incorporates traction members that include paddles  404  mounted on rotors  403  that may rotate so that the paddles translate into the valley  103  between pillows to engage the inflated portion of a pillow, as shown in  FIG. 10 . A pair of rotors with associated paddles  404  can be mounted above and below the path of the continuous strip of pillows  101 . The paddles  404  can move the pillows  101  forward, or fix the pillows in position to separate a segment of the pillows from the continuous strip  100 . The paddles  404  can alternatively work independently of each other so that while one paddle holds the continuous strip of pillows  101 , the other paddle tears off and dispenses a segment of the pillows  101 . 
     In another embodiment of the invention, the location of the perforation  104  between the pillows is identified by the use of a pillow position detector, which can include a sensor, such as a sensor that employs a vacuum directed towards the surface of the pillows  101 . As shown in  FIG. 9 , a tube  308  or other orifice is directed towards the contour of the pillow material and comes in close proximity to the surface of the pillow  101  when the high points of the pillow pass by it. A vacuum is applied to the tube  308  so that negative air pressure is registered when the end of the tube  308  is adjacent to the high points of the pillow contour. However, when the valleys  103  between the pillows  101  pass by the end of the tube  308 , the air pressure in the tube  308  changes, thereby identifying the location of the perforated section between the pillows  101 . This information is conveyed to the motor controller  20  so that movement of the continuous strip of pillows  100  can be stopped at the proper location. In other embodiments of the invention, other types of sensors can be used in a similar manner to identify the perforated section between the pillows. For example, an optical sensor may be used to identify markings placed on the film material at the perforated sections. 
     Another embodiment of the apparatus, illustrated in  FIGS. 11-15 , incorporates a rotating drum  501  mounted in a support frame  510 , to transfer and dispense pillows  101  formed by a pillow inflation and sealing device. The rotating drum  501  rotates about a central axis extending through a central support shaft  502  that extends transversely from the rotating drum  501 . The central support shaft  502  is mounted on the support frame  510  and supports the rotating drum  501 . The drum  501  is rotated by a drive mechanism  503 , for example, a chain or belt driven wheel that is mounted adjacent to the rotating drum  501  and rotates about the central axis of the central support shaft  502 . The drive mechanism  503  is operably connected to rotating drum  501  so that the drum  501  rotates when the drive mechanism  503  is driven, for example, by a motor and drive assembly. Preferably, the motor and drive assembly are mounted on the support frame  510 . Other methods of driving the rotation of rotating drum  501  are well known in the art and may also be incorporated. The rotating drum  501  is formed from two spaced apart circular plates  520 , 521  with interior support members, to provide interior support to the pillows, such as rods  519  extending between the plates. The rods  519  are preferably positioned in sets to define pocket areas  530  between the sets, and the pockets  530  are preferably configured to receive formed and inflated pillows  101  to be engaged and held as they are transferred through the apparatus by the rotation of rotating drum  501 . Sets of rods  519  are preferably positioned in adjacent pairs, such as pairs of rods  522 . Pairs of rods  522  are provided as traction members and can be spaced to receive the valleys  103  between inflated portions  105  of the continuous strip of pillows  100 . These pairs of rods  522  can be radially positioned about the center of plates  520 , 521  near the outer circumference of the plates at a spacing to match the spacing between pillows  101 . The pairs of rods  522  are preferably evenly spaced from each other in embodiments that employ pillows of a single configuration. As shown in  FIGS. 11-13 , other sets of rods  523  may be positioned between circular plates  520 , 521 , being attached to the plates through holes disposed thereabout. 
     The interior support members can also include biasing members to support the pillows  101  when they are in the pockets. In one embodiment, for example, the biasing members include platforms  524  that are relatively rigid, and which are preferably positioned between the pairs of rods  522 , adjacent the pockets  530 , and configured to support the inflated portion  105  of the pillows  101  as the pillows are rotated about the drum  501 . The platforms  524  can be positioned about the center of the plates  520 , 521 , and are preferably disposed radially inward from the pairs of rods  522 . More preferably, the platforms  524  are positioned at least about ½ inch and at most about 4 inches inward from the pairs of rods  522 , and more preferably at least 1 inch and at most 2 inches inward from the pairs of rods  522 . In this configuration, the platforms  524  deflect the inflated portions  105  of the pillows  101  radially outward to bias the inflated portions  105  of the pillows  101  against an exterior support member, such as outer guide surface  512 , to spread the inflated portions laterally due to the air pressure so to facilitate cutting and detachment of the pillows  101 . This also helps engage the chain of pillows to more positively draw the chain along the path from input to output of the apparatus. Additionally, once the pilots are detached from each other, the platforms  524  retain the detached pillows  101  against the guide surface  512 , preventing them from falling into the center of the drums, so that they can be held by the device until reaching the outlet or output section. 
     Preferably, the platforms  524  have a concave shape, such as to match the profile of the inflated pillows  101 , but in other embodiments, the platforms can be flat or convex. The platforms can also be discontinuous. In alternative embodiments, biasing members platforms  524  can be replaced or supplemented by at least one, and preferably two, resilient biasing members, as shown in  FIG. 13B . Preferably, the biasing members are springs, such as coil springs  624 , that are positioned transversely between the circular plates  620 , 621  of the drum  601 , although other orientations can be used. Similar to the platforms, the biasing members are configured to resiliently deflect the inflated portions  105  of the pillows  101  radially outward. Advantageously, the transverse tension of the biasing members provides a radial give when supporting the pillows  101 . The coil springs  624  are preferably connected to each of the plates  620 , 621  by a retaining member, which can include, for example a pin received in an opening in the plates  620 , 621 , which can be held in place by a transverse pin, such as a cotter pin. 
     As shown in the embodiment of  FIG. 13B , a connecting member  625  can be associated with and disposed between the pair of coil springs  624 . The connecting member  625  is preferably flexible, but can alternatively be rigid or semirigid, and is preferably a sheet of flexible material, which can be a fabric, plastic, leather, or other material. The connecting member can alternatively have a single layer extending from one spring to the other, and can alternatively comprise one of more strings or ties without a wide flat surface as shown in  FIG. 13B . The connecting member  625  is preferably configured for limiting spreading or separating of the pair of coil springs  624  in a circumferential direction so that a pillow  100  does not slip therebetween, and also for providing further biasing support in the radial direction to the inflated portion  105  of the pillow. Preferably, the connecting member  625  is a square shaped centrally disposed between the two plates,  620 , 621  and the pair of coil springs  624 , and more preferably the connecting member is between about 1 to 4 inches square. In other embodiments, the pair of coil springs  624  do not have a connecting member associated therewith. 
     The apparatus of the preferred embodiment also preferably includes a feed roller  540  that is preferably positioned adjacent the feed area  541  where the strip of pillows  100  first engages the drum  501 . The feed roller  540  is mounted on the support frame  510  with an axis of rotation that is preferably substantially parallel to the axis of rotation of the drum. The feed roller is configured to direct the strip of pillows  100  into the space  530  between the interior support members  524  and the exterior support member  512  as the strip is fed on the drum  501 . In this configuration, the roller  540  can rotate as the chain of pillows  100  passes thereby to smoothly feed the strip  100  onto the drum  501  with the inflated portion  105  of each pillow  101  between the pairs of rods  522 . Preferably, the strip of pillows  100  passes below the feed roller  540 , but it alternative embodiments, the strip can instead pass over the feed roller depending on the direction from which the pillows are fed to the apparatus. 
     The apparatus preferably includes a guide  512  that has an exterior support member to cooperate with the interior support members to engage and move the pillows. Guide  512  is mounted at the top of the support frame  510 , and preferably has an arcuate surface configured to cover a substantial portion of the top half of the drum  501 . In this configuration, the guide  512  can engage and contact the pillows  101  to guide and retain them against the drum as they are rotated thereabout to prevent or substantially reduce the risk of jamming. More preferably, the guide  512  is fixed only to the top of support frame  510  such that front and rear ends of the guide  512 , which are preferably adjacent, respectively, the feed area  541  and the dispensing area  542 , are radially flexible or displaceable to pivot away from the drum  501  to facilitate and dispensing of the strip of pillows  100 . The front end of the guide  512  that is adjacent the feed area  541  preferably includes a curved lip  545  to promote easier reception and engagement of the strip of pillows onto the drum  501 . 
     The combination of the rods  519  and platforms  524  between the plates  520 , 521  form pockets  530  in which inflated pillows  101  fed into the apparatus are engaged and held. As the rotating drum  501  rotates, the continuous strip of pillows  100  is drawn into the feed area  541  of the apparatus and moves through the apparatus. As each pillow  101  moves through the apparatus towards the dispensing area  542 , a dispensing member, which is preferably a finger formed by a fixed plate and positioned to extend perpendicularly through portions of platform  524  as they move past the fixed plate, “pushes” the pillow  101  out of the pocket  530 , thereby dispensing the pillow  101  at the dispensing area  542 . 
     Referring to  FIGS. 14 and 15 , the apparatus preferably includes a detachment mechanism  560  configured for detaching and separating the pillows  101  at their respective perforations  104 . The detachment mechanism  560  is preferably mounted to the support frame  510  above the drum  501 . The detachment mechanism  560  includes at least one detachment element, such as a cutter, and more preferably a pair of cutters  561 , 562 , as shown in  FIG. 14 . The detachment mechanism is configured for cutting, piercing, or otherwise detaching adjacent pillows  100  at a perforations  104 . The cutters  561 , 562  are preferably configured for rotating downwardly through the strip  100  in opposing directions (e.g., cutter  561  rotating counterclockwise and cutter  562  rotating clockwise), preferably substantially transversely to the path in which the pillows are drawn through the apparatus. The cutters  561 , 562  cooperatively puncture the perforated or otherwise weakened region  104 , preferably at a central portion, and move through the perforated region outwardly to completely separate the strip at the perforation. The outward, opposing movement of the cutters cooperatively pulls the material that is being cut against the opposing cutter. As shown in  FIG. 15 , the cutters  561 , 562  are configured to pass between a pair of rods  522  as they rotate to separate the strip. The rods  519  in each pair of rods  522  are preferably closely spaced to allow the longitudinally overlapping cutters to pass therebetween while closely supporting the adjacent pillow chain material. As shown in  FIGS. 14 and 15 , the detachment mechanism  560  is preferably positioned above the drum such that the cutters  561 , 562  first engage and puncture the strip of pillows  100  about three-quarters of the way along the path of their downward stroke. In an alternative embodiment, the detachment mechanism can be disposed within the drum, such as by mounting on the drum drive-shaft. 
       FIG. 17  shows another preferred embodiment of the cutters  761 , 762  of detachment mechanism  760 . The cutters  761 , 762  are configured for rotation in the downward direction in opposing directions through the film of the pillow chain, preferably substantially transversely to the path in which the pillows are drawn through the apparatus. The edges of the cutters  761 , 762  that engage and separate the pillows preferably are blunt or rounded, most preferably without any sharp edges. The cutters  761 , 762  include a major curved edge  764  and a blunt, preferably squared, reflex tip  765 . Thus, as the cutters  761 , 762  are rotated downward into the film, the major edge  764  of the cutters first engages and punctures the perforation  104  as they bias the material downward against the internal support members to break the perforation as the film on either side thereof is supported by the internal support members. The reflex tip  765  can then catch any remaining or intact portions of the perforation  104 , such as at the lateral edges of the film, during the upward rotation of the cutters for tearing and completing separation of the pillows  101 . The reflex tip can catch both edges and tear them by biasing them away from each other. In other embodiments, the detachment element can include other shapes and configurations that are effective for separating the perforations. 
     The detachment mechanism  560  also includes a motor  565  or other suitable drive mechanism that can drive a transmission  566  to operate the cutters. The cutters  561 , 562  are driven to rotate to the strip of pillows. In one embodiment, the apparatus includes a controller that is preferably associated with the detachment mechanism, drive mechanism, sensor, and drum for controlling the rotation of the drum and operation of the detachment mechanism. 
     As the strip of pillows  100  is rotated through the apparatus, the strip is separated by the detachment mechanism  560  depending on the desired length of pillows that is required to be dispensed. For example, the strip of pillows  100  is engaged and held against the drum  501  such that the inflated portions  105  of each pillow  100  are held within the pockets  530 , and the valleys  103  between the pillows  101  are positioned adjacent the pairs of rods  522 . Preferably, each perforation  104  at the valley  103  is disposed over and between the pair of rods  522 . Thus, when a specific length of pillows is desired, the controller of the apparatus preferably rotates the drum  501  adjacent to the detachment mechanism  560  such that the pair of rods  522  and the perforation  104  disposed thereover is aligned with the cutters  561 , 562 . The controller then operates the detachment mechanism  560  to rotate the cutters  561 , 562  to engage and separate the strip  100  at the perforation  104 . 
     While the various embodiments of the detachment mechanism described above have been found to be particularly effective and beneficial for separating strips of pillow that are transported through the transfer and dispensing apparatus of the present invention, it can be readily appreciated that the detachment mechanism can also be used in conjunction with other devices, such as pillow manufacturing machines or other preformed film handling devices, for separating strips of pillows, such as disclosed, for example in U.S. Pat. No. 6,932,134, the disclosure of which is hereby incorporated herein by reference thereto, in which the detachment mechanism can be used to break off a length of an inflated-pillow chain. Also, an alternative embodiment can be provided without cutters or alternatively without another detachment mechanism, and the pillows can be detached simply by tearing them from each other by hand, or by pulling the protruding pillow from the apparatus. 
     In another embodiment, as shown in  FIG. 16 , the internal support members of the drum include fixed or removable bar members  719  instead of pairs of rods  619 . The bar members  719  preferably include a pair of rigid slats  721  that extend the length of the bar member  719  and define a spacing  723  therebetween. The bar members  719  are configured for extending between the plates, and similar to the pairs of rods  619 , are preferably radially positioned about the center of the plates near their outer circumference to define pocket areas for receiving formed and inflated pillows  101 . Preferably, the bar members are retained in slots  720  of each of the plates, and in one embodiment, the bar members are magnetically retained in the slots, such as by a magnet and a ferrous material operatively associated on the bar member and plates. The bar members  719  are be spaced to receive the valleys  103  between inflated portions  105  of the continuous strip of pillows  100 , with the perforations  104  generally disposed over and aligned with the spacing  723 . The bar member  719  is thus configured for allowing the detachment element of the detachment mechanism to pass between the slats  721  and within the spacing  723  to engage and cut the perforation  104  between adjacent pillows  101  when the drum is rotated to position the bar member  719  adjacent the detachment mechanism. The slots can be circumferentially spaced at selected intervals, which can be regular or irregular. The removable bar members can be placed in all or fewer than all of the slots according to the distance between pillows to be detached, or to accommodate a predetermined number of pillows to be detached. In one embodiment, the slots are positioned at 2 inches radially from each other, so optional supported longitudinal lengths of pillow chains that can be accommodated between the internal support members include multiples of 2 inches. 
     In alternative embodiments, the drum is adjustable such that it can be configured to accommodate pillows  101  of varying dimensions. In one embodiment, the drum can be configured to handle chains of pillows having different lateral widths. For example, a drum can be configured to handle chains of pillows having lateral widths of both 8 inches and 10 inches. 
     This is preferably done by adjusting the spacing between the circular plates of the drum, or by inserting a spacer member adjacent to one of the plates to account for the decrease in lateral width of a chain of pillows. 
     Additionally, the drum can also be adjusted to handle chains of pillows having different length of pillows, as defined by the perforation-to-perforation length of the chain. For example, one embodiment of a drum can include pairs of rods spaced about the drum that are configured to engage the perforations between pillows having a perforation-to-perforation length of about 8 inches. However, the same drum can also be reconfigured to engage a strip of pillows that have a perforation-to-perforation length of, for example, about 4 inches. To achieve this, additional internal support members are attached about the drum (i.e. between the circular plates) and in between existing pairs of internal support members. In this configuration, the additional pairs of bars define pockets that can accommodate a strip of pillows having a perforation-to-perforation length of about 4 inches rather than 8 inches. The controller can then be set to stop the rotation of the drum in a position such that the any of the pairs of internal support members are adjacent detachment mechanism. As described above, the controller can operate the detachment mechanism to rotate the cutters to engage and separate the strip of pillows at any of the perforations. 
     In another embodiment, the drum is adjustable to handle chains of pillows having different pillow depths, for example, of pillows inflated to different internal pressures or having different configurations. To achieve this, the biasing members (e.g. the platforms or springs) can be adjusted and repositioned about the circular plates. 
     In other embodiments, the pairs of bars, the biasing members, and the circular plates can be adjusted as desired such that the drum can accommodate pillows of any dimension. 
     Preferably, the drum  501  is locked during activation of the detachment mechanism  560  to prevent the drum from rotating while the strip is being separated. For example, the apparatus may include a locking mechanism such as a solenoid  580  that is controlled by the controller to move a locking member  581  to engage one or both of the plates and prevent rotation of the drum during detachment of the strip. After detachment is complete, the controller preferably operates the locking mechanism to disengage the locking member, and the drum can rotate to dispense the length of pillows from the apparatus. 
     In yet another embodiment shown in  FIGS. 18A ,  18 B, and  19 , the apparatus  910  also includes an intake member  920  and an output member  930  for more easily facilitating entry and exit of the strip of pillows  100  into and from the apparatus. For example, the intake member  920  can be an intake funnel  922 , which is preferably aimed upwardly into the housing  905  and includes a flared bottom skirt  921 , which faces upstream and is preferably flared radially about its periphery. The intake member enables easier engagement of the pillow strip  100  onto the drum because the strip does not have to be exactly aligned and centered with the apparatus  910  in order for the pillows to be properly seated on the drum. Additionally, the orientation of the funnel  922  and intake throat  923  of the intake member with respect to the apparatus directs and aligns the pillow chain for generally tangential movement and engagement of the strip  100  onto the rotating drum for easier seating of the pillows thereon. The intake funnel  922  preferably includes an attachment portion, such as a flange  915 , that is configured for removable attachment to the housing of the apparatus  910 , as shown in  FIG. 19 . The housing  905  encloses the drum and the detachment mechanism, and includes an intake opening  907  to receive a pillow chain from the intake member  920  and an output opening  909  to outlet pillows to the output member  930 . 
     The output member  930  can include a guide chute  931  that is preferably attached adjacent to the output area of the apparatus housing, and more preferably generally adjacent and below the horizontal end portion of the drum, so that the dispensed strip of pillows  100  can naturally fall onto the chute  931 , which directs the strip away from the apparatus as desired. The guide chute  931  is also preferably removably and adjustably attached to the housing of the apparatus  910 , for example by retaining members or pins, so that the angle of the guide chute  931  relative to the apparatus  910  can be adjusted as desired. The chute can have side walls to direct the pillow chain to keep it on the chute in a lateral direction. An optional guide roller  933  can be disposed near the end of the intake member and the exterior support member  512  to help position and engage the pillow chain onto the drum. 
     The internal support members of  FIG. 18B  are preferably removable, and include first and second bars  940  inclined with respect to lateral slots  942  in the side walls of the plates  620 , 621 . The slots  942  are aligned with the opening between the bars  940  and with the path of the cutters as they rotate laterally past the plates  620 , 610 . Bars  940  are preferably inclined towards each other at their radially-outward ends. 
     It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the present invention without departing from the spirit or scope of the invention. For example, the detachment mechanism preferably completely detaches the dispensed pillow or pillows, but can alternatively initiate detachment or partially detach the pillow or pillows to facilitate final detachment by the user. Also, the components of the various embodiments can be interchanged with other embodiments. Thus, it is intended that the present invention include modifications and variations that are within the scope of the appended claims and their equivalents.