Abstract:
A packaging material handling device is disclosed. The device includes a first pair of traction members configured for cooperatively engaging a chain of pre-inflated pillows from opposite sides thereof and being operable for driving the chain in the flow direction. The device further includes a second pair of traction members configured for cooperatively engaging the chain from opposite sides thereof. The second pair of traction members are spaced apart from the first pair of traction members along a flow direction and are operable for driving the chain in the flow direction. The first and second pairs of traction members are operable for holding the first and second portions of the chain during a breaking operation. The device further includes a breaking member disposed between the first and second pairs of traction members and movable against the chain across the flow direction in the breaking operation to break the chain for detaching the first portion from the second portion.

Description:
FIELD OF THE INVENTION 
       [0001]    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 
       [0002]    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. 
         [0003]    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. 6,932,134 and pending U.S. Patent Application Pub. Nos. 2006/0292320 and 2006/0251833. 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 can 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. 
         [0004]    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. 
         [0005]    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 
       [0006]    The present invention relates to a packaging material handling device. The preferred embodiment of the device includes a first pair of traction members configured for cooperatively engaging a chain of pre-inflated pillows from opposite sides thereof and being operable for driving the chain in the flow direction. The device further includes a second pair of traction members configured for cooperatively engaging the chain from opposite sides thereof. The second pair of traction members are spaced apart from the first pair of traction members along a flow direction and are operable for driving the chain in the flow direction. The first and second pairs of traction members are operable for holding the first and second portions of the chain during a breaking operation. The device further includes a breaking member disposed between the first and second pairs of traction members and movable against the chain across the flow direction in the breaking operation to break the chain for detaching the first portion from the second portion. 
         [0007]    In a preferred embodiment, the breaking member is in the form of a blade including a substantially blunt leading edge. The leading edge can include a central lobe and a pair of outer lobes, the central lobe being disposed between the pair of outer lobes. Recessed areas can be disposed between the central lobe and the outer lobes, with a sloped surface extending from the central lobe into the recessed areas, such that the lobes contact the weakened area of the chain before the recessed area and the sloped surface gradually breaks the weakened area of the chain as the blade moves therethrough during the breaking operation. 
         [0008]    In a further embodiment the packaging material handling device includes a first set of rollers configured for cooperatively engaging a chain of pre-inflated pillows from opposite sides thereof and being operable for driving the chain in the flow direction and a second set of rollers configured for cooperatively engaging the chain from opposite sides thereof. The second set of rollers can be spaced apart from the first set of rollers along a flow direction and can be operable for driving the chain in the flow direction. The first and second sets of rollers can be operable for holding the first and second portions of the chain during a breaking operation. At least some of the rollers, from at least one of the first and second sets of rollers, are preferably disposed on each side of the chain are staggered with respect to the rollers on the opposite side of the chain for engaging the chain at different lateral locations for deforming the chain. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    These and other objects, features and advantages of the invention will be apparent from a consideration of the following non-limiting detailed description considered in conjunction with the drawing figures, in which: 
           [0010]      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; 
           [0011]      FIG. 2  is a perspective view of the automated transfer and dispensing apparatus of  FIG. 1 ; 
           [0012]      FIGS. 3A-3D  are front views of the apparatus of  FIG. 2  showing various configurations for traction elements used therein; 
           [0013]      FIG. 4  is a side view of the apparatus of  FIG. 2 ; 
           [0014]      FIG. 5  is a top view of the apparatus of  FIG. 2 ; 
           [0015]      FIG. 6  is a perspective view of a breaking mechanism used in the apparatus of  FIG. 2 ; 
           [0016]      FIGS. 7A-7D  are various configurations for blades that can be used in the breaking mechanism of  FIG. 6 ; 
           [0017]      FIG. 8  is a perspective view of a removable tray used in the apparatus of  FIG. 2 ; and 
           [0018]      FIG. 9  is a top view of a film that can be used to form a chain of pre-filled packaging pillows for transfer and dispensing using the apparatus of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    In  FIG. 1 , a preferred embodiment of the transfer and dispensing apparatus, which can be configured as an air-pillow burster or dispenser  10 , is shown positioned adjacent to and above the location of a holding bin  2 . The holding bin  2  may be used to collect void-fill or another type of packaging protective pillows  101  formed on a continuous chain  100  of adjacent pillows, as described, for example, in U.S. Patent Application Pub. No. 2006/0251833, the disclosure of which is incorporated by reference herein. As the pillows are inflated and sealed by a pillow inflation and sealing device  5 , for example, as disclosed in U.S. Pat. No. 6,932,134, or U.S. Patent Application Pub. No. 2008/0066852, the disclosures of which are incorporated herein by reference. Preferably, the pillows filled with a fluid, and more preferably a gas, such as air. As inflated pillows  101  are formed by the pillow inflation and sealing device  5 , they fall into the holding bin  2  in continuous chain  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 . 
         [0020]      FIG. 9 , shows a typical web or strip  110  of uninflated material to be inflated and sealed into a series of pillows attached at perforated edges. The web  110  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  110  has a top edge  112  and a bottom edge  114 , both of which are closed. The web  110  includes generally transverse seals  116  and generally transverse perforations  618 . The transverse seals  116  join a top sheet  120  of the web  110  to a bottom sheet  122  of the web  110  along the seals  116 , while the transverse perforations  118  perforate the web through the top and bottom sheets  120  and  122 . In a preferred embodiment of web  110 , the perforations are formed within the transverse seals, which preferably have a width sufficient for the formation of the perforations. According to the embodiment shown, the transverse seals  116  begin at the bottom edge  114  of the web  110  and extend to a distance d from the top edge  112 . The web  110  has a width  130 , and a perforation-to-perforation length  132 , which may be altered depending on the particular type of pillow to be manufactured. As further shown in  FIG. 9 , web  110  can include a plurality of longitudinal seal segments  152  that separate the individual pillows  101  into a plurality of polygonal sections  190  connected by at least one, but preferably two, oppositely-disposed channels  194  configured to permit air flow between sections  190 . 
         [0021]    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 burster  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 . 
         [0022]    Burster  10  is shown in detail in  FIGS. 2-5 , and includes an inlet  12  and an outlet  14 . A driving mechanism  16  is configured to move the continuous strip  101  of inflated pillows  100  through the burster  10  in a downstream direction  18  from inlet  12  and out from outlet  14 . Driving mechanism  16  is further configured to hold the chain  100  in an appropriate position during a breaking operation. A breaking mechanism  40  is configured to carry out the breaking operation by moving braking member, which is preferably in the form of a blade  42 , into contact with a selected perforation  118  and forcing braking member  42  through the perforation  118  to cause the perforation  118  to tear in order to form a strip segment of a desired number of pre-inflate pillows for use during a packing operation. 
         [0023]    Driving mechanism  16  includes a first pair of oppositely-disposed traction elements  20   a , 20   b  and a second pair of oppositely-disposed traction elements  22   a , 22   b . Each pair of traction elements  20   a , 20   b  and  22   a , 22   b  is configured to co-operatively grip the chain  100  of pre-inflated pillows  101  in order to move the chain  100  therethrough and to hold chain  100  during the breaking operation, both without tearing through one of the web layers  120 , 122  or creating too great a pressure within a pillow  101  resulting in popping thereof. The pairs of traction members  20   a , 22  and  22   a , 22   b  are further configured to move the chain  100  in a substantially straight path in downstream direction  18 , such that the perforations  118  remain substantially aligned with breaking member  42  and such that chain  100  does not travel laterally within burster  10 , which could result in chain  100  pushing up against a portion of the housing  11  of device  10  and could lead to jamming of burster  10  or damage to the chain  100 . 
         [0024]    Each pair of traction elements  20   a , 20   b  and  22   a , 22   b  consists of an upper element  20   a , 22   a  and a lower element  20   b , 22   b , wherein the upper element  20   a , 22   a  is disposed so as to contact the top of chain  100  as it passes therethrough, and wherein the lower element  20   b , 22   b  is disposed so as to contact the bottom of chain as it passes therethrough, the upper element  20   a , 22   a  being substantially vertically aligned with the corresponding lower element  20   b , 22   b.    
         [0025]    Referring to the second pair of traction elements  22   a , 22   b , each traction element  22   a , 22   b  consists of an axle  24  rotatably affixed to housing  11  and extending perpendicularly to the flow direction  18  across the width of the interior of housing  11 . Axle  24  has a plurality of rollers  26  affixed thereto that are configured to contact chain  100  so as to move chain  100  in the flow direction  18  and to hold chain  100  during the breaking operation. Rollers  26  can include an elastomeric outer surface to aid in gripping chain  100  form moving and holding thereof. In a preferred embodiment, rollers  26  are made from an elastomeric material such as carboxylated nitrile. By forming rollers  26  from an elastomeric material, rollers  26  can frictionally grip chain  100  without causing damage thereto. Further, some of the elastomeric rollers  26  can be biased against one another, such as a roller of the upper traction element  22   a  and a corresponding roller of the lower traction element  22   b , causing deformation of the rollers  26 , which allows for increased gripping pressure against a portion of chain  100 . 
         [0026]    Rollers  26  are preferably in the form of a cylinder having a diameter of between about 1.5 in. and about 3 in. In a preferred embodiment the diameter of rollers  26  is about 2 in. Rollers  26  preferably further have a width of between about ¼ in. and about ¾ in., and more preferably about ½ in. Rollers  26  also preferably include a fillet at the outside edges of the film-contacting surface thereof. The fillet preferably forms an angle of about 45° and extends into the film-contacting surface by between about 0.01 in and about 0.05 in, and more preferably about 0.03 in. 
         [0027]    The number of rollers  26  included along each of axle  24   a  of upper traction element  22   a  and axle  24   b  of lower traction element  22   b  and the spacing between adjacent rollers on each axle  24   a , 24   b  can vary and can be selected to suitably grip a number of differently-configured chains of pre-inflated pillows. The various configurations of the chains include various chain lateral widths, various perforation-to perforation longitudinal lengths, varying pillow thicknesses and pillows having different sizes or geometries. An exemplary arrangement of rollers  26  for one pair of traction elements  22   a , 22   b  is shown in  FIG. 3 , wherein the outside rollers  26   a  are aligned in a vertical direction with a corresponding roller on the other axle. Further, in the arrangement of  FIG. 3 , inside rollers  26   b  are in a staggered relationship between those positioned on the upper axle  24   a  and the lower axle  24   b . This staggered relationship is such that the inside rollers  26   b  on the upper axle  24   a  do not have a roller positioned vertically below them and such that the inside rollers  26   b  on the lower axle  24   b  do not have a roller positioned vertically above them. The spacing between adjacent inside rollers  26   b , one being positioned on upper axle  24   a  and the adjacent one being positioned on the lower axle  24   b , can be at a lateral distance  30  that is adequate for the adjacent inside rollers  26   b  to interact with a pillow  101  that extends between the adjacent inside rollers  26   b  to cause or increase pressure between the inside roller  26   b  and the surface of the pillow  101  by deforming pillow  101  as shown in  FIG. 3A , which preferably causes an increase in the pressure within pillow  101  sufficient to create a pinch-point or pinch region between the inside rollers  26   b  without causing the pillow to rupture. Because burster  10  is preferably acceptable for use with a plurality of different configurations of chains  100 , as stated above, distance  30  can be sufficient to create at least enough pressure to cause a level of useful friction between the pillow surface and the inside rollers  26   b  across the range of chain  100  configurations for which it is intended without causing any of the pillows  100  within the various chain  100  configurations to rupture. As shown in  FIG. 3B , the inside roller  26   b  configuration of  FIG. 3A  is also sufficient to cause deformation of a pillow  101 ′ that is divided into a plurality of segments  190 , which causes the desired friction between pillow  101 ′ and inside rollers  26   b . In such an embodiment, it is preferred that the seal segments  152  do not extend all the way across pillow  101 , leaving a channel  194  between pillow segments  190  that allows air to move among the pillow segments  190 . In such an arrangement, if one of the pillows  190  is pinched by roller  26 , the air can move through a channel  194  to the remaining pillows  101 , thereby preventing rupture of the pinched pillow segment. In a further preferred embodiment, a channel is formed on each side of the seal segments  150  so that if one channel is pinched by rollers  26 , if necessary, air can still travel between pillows  190  through the non-pinched channel. Preferably the two channels are spaced apart at a distance sufficient to prevent pinching of both channels simultaneously. 
         [0028]    The film material used to form the chain  100  of pre-inflated pillows  101 , is preferably formed having an inflation channel  198 , as shown in  FIG. 10 , that is cut open during the inflation process to leave a flap of uninflated plastic along an edge of the chain  100 . Because of the extra, uninflated plastic located along one side of the chain  100 , it can be advantageous to have more rollers toward the side of the chain  100  having the inflation channel  198 . This can include positioning the rollers  26  along the axles  24   a , 24   b  such that the distance between adjacent rollers is less toward the end with the inflation channel  198 . Further, an additional pair of rollers  26   c  can be positioned to the outside of the outside rollers  26   a  to align with the inflation channel  198 , as shown in  FIG. 3C . 
         [0029]    In a further alternative arrangement, shown in  FIG. 3D , rollers  26  of upper axle  24   a  can be vertically aligned with a corresponding roller  26  of lower axle  24   b . In such an arrangement, it is not necessary that the width of the chain  100  extend across all rollers. 
         [0030]    The arrangement of rollers  26  of axles  25   a , 25   b  of the first pair of traction elements  20   a , 20   b  can be the same or different from the arrangement of rollers  26  of the second pair of traction elements  22   a , 22   b . Any of the various roller arrangements discussed above with respect to the second pair of traction elements  22   a , 22   b  is suitable for use with the second pair of traction elements  20   a , 20   b . The arrangements of the rollers  26  in each of the first pair of traction elements  20   a , 20   b  and second pair of traction elements  22   a , 22   b  can be selected to interact with each other to provide the desired movement and holding characteristics for device  10 . The use of substantially the same roller arrangement in both the first pair of traction elements  20   a , 20   b  and the second pair of traction elements  22   a , 22   b  can provide improved holding characteristics for device  10  during the breaking operation. 
         [0031]    As shown in  FIG. 4 , the first and second pairs of traction elements  20   a , 20   b  and  22   a , 22   b  are spaced apart from each other in the flow direction  18  such that the a gap of a distance  32  is formed between the rollers  26  of the first pair of traction elements  20   a , 20   b  and rollers  26  of the second pair of traction elements  22   a , 22   b . Distance  32  is preferably sufficient to provide clearance for blade  42  to fit therebetween, while providing the desired tension of chain  100  around perforation  118  during the breaking operation. Distance  32  is further preferably sufficient such that the leading end of the chain  100  (which can be created along a perforation  118  by the breaking operation) substantially aligned remains substantially aligned with the rollers of the second pair of traction elements  22   a , 22   b  as it is advanced in the flow direction  18  toward the rollers  26  to ensure proper engagement therewith. 
         [0032]    The first and second pairs of traction elements  20   a , 20   b  and  22   a , 22   b  are preferably configured to be driven by a single motor  34  such that all of the axles  24   a , 24   b , 25   a , 25   b  move at the same speed. As shown in  FIG. 4 , the output of motor  34  is connected by a belt  35  to axle  25   b  to cause rotation thereof such that the top end of rollers  26  affixed thereto move in the flow direction  18 . A series of gears  36  interconnect axles  24   a , 24   b , 25   a , 25   b  such that the driving motion of axle  25   b  causes synchronous movement of the remaining axles  24   a , 24   b , 25   a  such that the rollers  26  move in the appropriate directions to cause movement of the chain  100  in the flow direction  18 . Gears  36  are all the same size in order to cause all traction elements  20   a , 20   b , 22   a , 22   b  to rotate at the same speed. The interconnected arrangement of axles  24   a , 24   b , 25   a , 25   b  is such that during the breaking operation, when blade  42  is pressed into chain  100 , traction elements  20   a , 20   b , 22   a , 22   b  do not rotate, thereby holding chain  100  substantially stationary during the breaking operation. 
         [0033]    As stated previously, the breaking operation is carried out by breaking mechanism  40 , as shown in  FIG. 6 , that includes blade  42  affixed to a holder  44  that travels vertically along rods  46 . The vertical travel of holder  44  is controlled by motor  48 . In a preferred embodiment, motor  48  is connected to holder by a rack-and-pinion system including gear  50  and rack  52  such that rotation of gear  50  in a first direction, such as the clockwise direction, causes movement of the holder  44  in the downward direction to cause blade  42  to tear chain  100  along perforation  118 . Holder is retracted, or moved in the upward direction by movement of gear  50 , caused by motor  48 , in the reverse, or counter-clockwise, direction. Alternative arrangements for causing movement of holder  44  are possible including a cam or crank arrangement between motor  48  and holder  40  or the use of a pneumatic or hydraulic system. 
         [0034]    A preferred embodiment of blade  42  is shown in  FIGS. 6 and 7A , wherein blade includes a leading edge  60  along a lower portion thereof. Leading edge  60  preferably has a thickness  62  defined by the thickness of the material used to make blade  42 . Preferably thickness  62  is between 0.01 in and 0.1 in. In and embodiment, thickness  62  is at least about 0.03 in. or, alternatively less than about 0.08 in. Preferably, thickness  62  is about 0.06 in., although other values for thickness  62  are possible. Blade  42  is further configured such that leading edge  60  defines a plurality of lobes on blade  42 , including central lobe  64  and side lobes  66  and  68 . In an embodiment, shown in  FIG. 7A , central lobe  64  forms a curved portion  70  at least near the center thereof. Curved portion  70  can extend across substantially all of central lobe  64  or central lobe  64  can form straight edges  65  along the remainder thereof. Further, curved portion  70  can have a radius  72  of between about 5 in. and 7 in and more preferably about 6 in. In the embodiment of  FIG. 7 , side lobes  66 , 68  are substantially identical and include a substantially straight edge along a lower portion  76  thereof, followed by a curved portion  78  that turns upwardly to meet with central lobe  64  at an interior corner  80  curved portion  78  preferably has a radius of between about 1 in. and about 2 in and more preferably about 1.25 in. Further preferably, lobes  64 , 66 , 68  are preferably configured such that the lowermost portions of each are substantially even in a vertical direction and such that interior corners  80  are spaced above the lowermost portions of lobes  64 , 66 , 68  by a distance  82  that is between about 1 in. and 2 in. and is more preferably about 1.3 in. 
         [0035]    In general leading edge  60  of blade  42  is configured to evenly and completely tear perforation  118  of chain  100  without deforming or otherwise damaging chain  100 , including pillows  101 , or without substantially altering the position of chain within burster  10 . The preferred embodiment of blade  42  shown in  FIG. 7A  is configured as such to tension chain  100  about perforation  118  between the first and second pairs of traction members  20   a , 20   b  and  22   a , 22   b  before blade  42  begins to tear chain  100  along perforation  118 . Blade  42  is further preferably configured to initiate the tearing of perforation  118  near the center thereof. This may be done simultaneously with initiating tearing of the perforation  118  near the outside ends thereof. 
         [0036]    Alternative configurations for blades that can be used in breaking mechanism  40  are shown in  FIGS. 7B-7D .  FIG. 7B  shows a variation of blade  242 , in which features similar to those of blade  42  are similarly numbered in the 200s, and in which outside lobes  266 , 268  have different shapes, lobe  266  having a rounded shape, while lobe  268  has a more pointed shape. Central lobe  264  of blade  242  also has a substantially more pointed shape compared to the arrangement of  FIG. 7A , and can be formed with a pointed end, without a curved portion, by the intersection of straight edges  265 . Straight edges  265  preferably form an angle  267  with a plane normal to the direction of movement of blade  242 , the plane being preferably substantially parallel to the flow direction  18 . In an embodiment, angle  269  is between about 5° and about 20°, and more preferably about 10°. Additionally lobes  266 , 268 , shown in  FIG. 7B  include an outside edge that is substantially even in a vertical direction with interior corners  280 .  FIG. 7C  shows a blade  342 , in which features similar to those of blade  42  are similarly numbered in the 300s, and in which outside lobes  366 , 368  are substantially similar to each other and include a serrated edge  367  formed thereon that is angled generally upward toward the outside edges of blade  342 . Serrated edge  367  includes a plurality of serrations  371 , each including a leading edge  373  and a connecting edge  375  that are configured such that the connecting edge makes contact with the chain  100  during the breaking operation to form a portion of the tear along perforation  118  and such that connecting edge  375  relieves the contact of the serrated surface  367  with perforation  118  such that the serrated surface  367  makes intermittent contact with perforation  118 . In an embodiment, the leading edge  373  is angled relative to a plane normal to the direction of motion of blade  42 . The angle of leading edge  373  can be within the range of angles for angle  269  discussed with respect to  FIG. 7B . The angle of leading edge  373  can also be substantially equal to the angle of straight portion  465 .  FIG. 7D  shows a blade  442 , in which features similar to those of blade  42  are similarly numbered in the 400s. Blade  442  has one lobe  468  with a serrated edge  467 , which can be similar to serrated edge  367  discussed with respect to  FIG. 7C , and another lobe  466  with a substantially straight edge  476  thereon, similar to that of lobe  66  shown in  FIG. 7 . 
         [0037]    The breaking mechanism  40  can also include a pair of parallel bars  41  that are spaced beneath a plane defined by the intersection of traction elements  20   a  and  20   b  and extending in the flow direction  18  to the intersection of traction elements  22   a  and  22   b . Bars  41  can be spaced beneath this plane at a distance sufficient to allow clearance thereover of pillows  101  as they pass through drive system  20 . Bars  41  are further spaced apart along the flow direction  18  at a distance slightly greater than the thickness of blade  42 . During the breaking operation, blade  42  extends into the space between bars  41  such that bars  41  can assist blade  42  during any tearing of perforation  118 , at which point a portion of chain  100  surrounding perforation  118  will deform so as to contact bars  41 . Such a configuration is shown in  FIG. 3A , in which blade  42  is in the breaking position such that leading edge  60  thereof is positioned below the top edge  45  of bars  41 , the chain  101  having been torn along perforation  118  (not shown in  FIG. 3 ). 
         [0038]    As shown in  FIG. 4 , inlet  12  of burster  10  includes a roller  90  to help guide chain  100  as burster  10  pulls chain  100  out of bin  2 . Roller  90  is preferably included on a removable tray  91  that can be attached and detached from burster  10  and that included inlet  12 . Tray  91  preferably includes a pair of rails  91  that are received within housing  11 . Tray also preferably includes a top cover  93 , a bottom cover  94  and side walls  95  and  96  that together define a guide  96  that is specifically sized for a chain configuration (or a plurality of similarly-sized chain configurations) intended for use with burster  10 . Guide  97  is configured such that the vertical centerline of the chain  100  is properly aligned with rollers  26  such that chain  100  is properly engaged with the drive system  20 . Guide  97  is further configured such that chain  100  is properly aligned in a lateral direction (perpendicular to flow direction  18 ) with rollers  26 . For example, such alignment can include properly aligning inflation channel  198  with rollers  26   c . Preferably, a number of different trays  91  are provided with burster  10  that can be interchangeably affixed with housing  11  depending on the size of the material to be used with burster  10 , the configuration of tray  91  corresponding thereto accordingly. 
         [0039]    A control system can be included in burster  10  that is configured to properly dispense a chain segment of a desired number of consecutive pillows  101  and to automatically separate the chain segment from the chain  100  by properly aligning the appropriate perforation  118  with blade  42  and for causing blade to tear chain  100  along the selected perforation  118 . To achieve the proper alignment of the appropriate perforation  118  with blade  42 , the control system can include an optical sensor  97  that is aligned with an edge of the chain  100  that includes a plurality of markings  121  that are spaced apart from a corresponding perforation at a distance that is substantially equal to the distance between sensor  97  and blade  42 . Accordingly, when a marking  121  is aligned with sensor  97 , the corresponding perforation  118  is aligned with blade. This allows the control system to count the number of markings that pass thereunder to keep track of the number of pillows  101  being dispensed and to stop the movement of the drive mechanism  20  such that a perforation  118  is aligned with blade  42  once a chain segment having the desired number of pillows  101  has been dispensed. The control system can additionally or alternatively be configured to be controlled by a user and to receive an input therefrom by, for example, a foot pedal. 
         [0040]    Additionally, the control system can include a sensor affixed to one of a number of fingers  98  that are affixed to a rod  99  extending across outlet  14  of burster  10 . Fingers  98  are generally configured to extend downwardly across the outlet  14  when there is no portion of chain  100  present in outlet  14 . Fingers  98  can, accordingly, be configured such that they can not rotate inwardly against the flow direction  18  which can add help prevent a user from accidentally reaching into outlet  14 , which could cause injury. Fingers  98  are also configured to ride across the upper surface of pillows  101  as they are dispensed from outlet  14 , and can further be configured to retain a chain segment within outlet  14  after the breaking operation, until a user removes the chain segment therefrom. Accordingly the sensor on one of the fingers  98  can be configured to detect the presence of a pillow within outlet  14  based on the position of the finger  98 . This arrangement can be used, for example, to prevent the device from dispensing pillows  101  after a breaking operation has been performed while a pillow  101  from a previously-dispensed chain segment is still present in outlet  14  or to provide an audible or visual signal to a user indicating that the outlet  14  should be cleared. The control system can also be connected to one or more emergency switches  99  that can be configured to allow a user to stop operation of burster  10  during an emergency situation. 
         [0041]    All of the references specifically identified in the detailed description section of the present application are expressly incorporated herein in their entirety by reference thereto. The term “about,” as used herein, should generally be understood to refer to both the corresponding number and a range of numbers. Moreover, all numerical ranges herein should be understood to include each whole integer within the range. 
         [0042]    While illustrative embodiments of the invention are disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the features for the various embodiments can be used in other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention.