Patent Publication Number: US-9844911-B2

Title: Air cushion inflation machine

Description:
RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/907,347, filed Nov. 21, 2013, the entire disclosure of which is hereby incorporated by reference. 
    
    
     INCORPORATION BY REFERENCE 
     This application incorporates by reference the entire disclosures of, to the extent they are not conflicting with the present application, U.S. patent application Ser. No. 13/543,082 entitled AIR CUSHION INFLATION MACHINE, filed Jul. 6, 2012, and U.S. Provisional Patent Application No. 61/505,261 entitled AIR CUSHION INFLATION MACHINE, filed Jul. 7, 2011. 
     BACKGROUND 
     The present invention relates to fluid filled units and more particularly to a novel and improved machine for converting a web of preformed pouches to dunnage units and will be described with particular reference thereto. It will be appreciated, however, that the invention is also amenable to other applications. 
     Machines for forming and filling dunnage units from sheets of plastic are known. Machines which produce dunnage units by inflating preformed pouches in a preformed web are also known. For many applications, machines which utilize preformed webs are used. 
     The present invention provides a new and improved apparatus and method which addresses the above-referenced problems. 
     SUMMARY 
     In one aspect of the present invention, it is contemplated that a machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form dunnage units. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides of the belts engage a surface of the web and pull the web past at least one sealing element. In one exemplary embodiment, a heating element is on a second side of the first belt not engaging the web and a compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element. The present application also discloses that compliant or softer material or a compliant or softer belt spreads the pressure applied to the sealed area more evenly, which results in a more uniform seal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to exemplify the embodiments of this invention. 
         FIG. 1  is a plan view of an exemplary embodiment of air cushion material; 
         FIG. 1A  is a top plan view of an exemplary embodiment of an air cushion inflation machine; 
         FIG. 1B  is a view taken along lines  1 B- 1 B in  FIG. 1A ; 
         FIG. 2  is a view similar to  FIG. 1A  with a web of air cushion material installed in the air cushion inflation machine; 
         FIG. 2A  is a plan view of inflated and sealed air cushions; 
         FIG. 3A  is a side view of an element made of compliant material; 
         FIG. 3B  is an end view of an element made of compliant material; 
         FIG. 4  is an illustration of a heating element having a higher resistance portion and a lower resistance portion; 
         FIG. 5  is a plot of DC heating element voltage switched between maximum and minimum voltages according to a duty cycle; 
         FIG. 5A  is a plot of an analog DC heating element voltage that is adjustable between maximum and minimum voltages; 
         FIG. 6  is a flow chart illustrating an exemplary embodiment of a control algorithm for an air cushion inflation machine; 
         FIG. 7A  is a flow chart illustrating an exemplary embodiment of an idle sequence of a control algorithm for an air cushion inflation machine; 
         FIGS. 7B-7C  illustrate an example of states of components of an air cushion inflation machine when the air cushion inflation machine is in an idle condition; 
         FIG. 8A  is a flow chart illustrating an exemplary embodiment of a start sequence of a control algorithm for an air cushion inflation machine; 
         FIGS. 8B-8E  illustrate an example of states of components of an air cushion inflation machine when the air cushion inflation machine is in a start condition; 
         FIG. 9  is a flow chart illustrating an exemplary embodiment of a run sequence of a control algorithm for an air cushion inflation machine; 
         FIG. 10A  is a flow chart illustrating an exemplary embodiment of a stop sequence of a control algorithm for an air cushion inflation machine; 
         FIGS. 10B-10C  illustrate an example of states of components of an air cushion inflation machine when the air cushion inflation machine is in a stop condition; 
         FIG. 11  illustrates one embodiment of alternating current (AC) to direct current (DC) converter (AC/DC converter) providing DC power to a system; 
         FIG. 12  a second embodiment of the alternating current (AC) to direct current (DC) converter (AC/DC converter) providing DC power to the system; 
         FIGS. 13 and 13A  are perspective views of an exemplary embodiment of an air cushion inflation machine; 
         FIG. 14  is a perspective view of a dual belt air cushion inflation machine, such as the air cushion inflation machine illustrated by  FIGS. 7B and 7C ; 
         FIG. 14A  is a side view of the air cushion inflation machine illustrated by  FIG. 14 ; 
         FIG. 15A  is a front view of sealing components of the air cushion inflation machine illustrated by  FIGS. 13 and 13A ; 
         FIG. 16  is a perspective view of the sealing and clamp assemblies of the air cushion inflation machine shown in  FIG. 14 ; 
         FIG. 17  is a view taken as indicated by lines  12 - 12  in  FIG. 16 ; 
         FIG. 17A  is an enlarged portion of  FIG. 17 ; 
         FIG. 17B  is a view similar to  FIG. 17A  illustrating routing of inflation cushion material into the machine; 
         FIG. 18  is a rear perspective view of a sealing assembly of the air cushion inflation machine illustrated by  FIG. 13A ; 
         FIG. 19  is a rear view of a sealing assembly of the air cushion inflation machine illustrated by  FIG. 13A ; 
         FIG. 20  is a perspective view of a sealing assembly of the air cushion inflation machine shown in  FIG. 14 ; 
         FIG. 21  is a view taken as indicated by lines  16 - 16  in  FIG. 20 ; 
         FIG. 22  is a view taken as indicated by lines  17 - 17  in  FIG. 20 ; 
         FIG. 23  is a perspective view of a clamping assembly of the air cushion inflation machine shown in  FIG. 14 ; 
         FIG. 24  is a view taken as indicated by lines  19 - 19  in  FIG. 23 ; 
         FIG. 25  is a partial rear view of the sealing and clamping assemblies shown in  FIG. 16 ; 
         FIG. 26  is a sectioned perspective view with the section being taken as indicated by lines  21 - 21  in  FIG. 25 ; 
         FIG. 27  is a sectional view taken along the plane indicated by lines  21 - 21  in  FIG. 25 ; 
         FIG. 28  is a partial rear view of the sealing and clamping assemblies shown in  FIG. 16 ; 
         FIG. 29  is a sectioned perspective view with the section being taken as indicated by lines  24 - 24  in  FIG. 28 ; 
         FIG. 30  is a sectional view taken along the plane indicated by lines  24 - 24  in  FIG. 28 ; 
         FIG. 31  is a perspective view of a part of an air cushion inflation machine illustrated by  FIG. 13A ; 
         FIG. 32  is a view taken as indicated by lines B-B in  FIG. 31 ; 
         FIG. 33  is a component diagram of an air cushion inflation machine; 
         FIG. 34  is a sectional view of the heated sealing element and the compliant material; 
         FIG. 35  is a perspective view showing an inside of the air cushion inflation machine; 
         FIG. 36  is a perspective view of another exemplary embodiment of an air cushion inflation system showing a curved belt surface; 
         FIG. 37  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 38  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 39  is a perspective view of a part of an air cushion inflation system showing a curved belt surface and the blower assembly; 
         FIG. 40  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 41  is a view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 42  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 43  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 44  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 45  is a perspective view of a part of an air cushion inflation system showing a curved belt surface; 
         FIG. 46  is a perspective view of a belt assembly including a curved belt surface; 
         FIG. 47  is a perspective view of a belt assembly including a curved belt surface; 
         FIG. 48  is a perspective view of a part of an air cushion inflation system showing a blower system; 
         FIG. 49  is a perspective view of a belt assembly including a curved belt surface; 
         FIG. 50  is a perspective view of a belt assembly including a curved belt surface; 
         FIG. 51  is a perspective view of a spindle for an air cushion inflation system; 
         FIG. 52  is a side view of a spindle for an air cushion inflation system; and 
         FIGS. 53 and 54  are perspective views of a spool for an air cushion inflation system. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT 
     As described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements. 
       FIG. 1  illustrates an example of a preformed web  10  that can be processed by a new machine  50  (See machine examples of  FIGS. 1A, 7C, 13, and 14 ) to produce inflated air cushions  12  (See  FIG. 2A ). The preformed web can take a wide variety of different forms. Any preformed web that can be inflated, sealed and then separated from the machine  50  can be used. Examples of acceptable webs  10  include, but are not limited to, any of the webs shown and/or described by U.S. Pat. Nos. D633792; 7897220; 7897219; D630945; 7,767,288; 7,757,459; 7,718,028; 7,694,495; D603705; 7,571,584; D596031; 7,550,191; 7,125,463; 7,125,463; 6,889,739; or 7,975,457; or United States Patent Application Publn. Nos. 20100281828A1; 20100221466A1; 20090293427A1; and 20090110864A1, which are all incorporated herein by reference in their entirety. It should be readily apparent that other preformed webs could be used in the machine  50  to produce dunnage units. 
     The illustrated web  10  is formed of a heat sealable plastic film, such as polyethylene. However, any heat sealable material can be used. The web  10  includes superposed top and bottom, elongate layers  14 ,  16  connected together along spaced seal and inflation side edges  18 ,  20 . Each of the edges may be either a fold or a seal. The superposed layers  14 ,  16  are hermetically connected along the seal side edge  18 . In the illustrated embodiment, the inflation side edge  20  is perforated. In another embodiment, the inflation side edge  20  is not perforated and a line of perforations is included in one of the layers  14 ,  16 , with the line of perforations being spaced apart from and running parallel to the inflation side edge  20 . In another embodiment, the inflation side edge  20  is not perforated and a line of perforations is included in each of the layers  14 ,  16 , with the lines of perforations being spaced apart from and running parallel to the inflation side edge  20 . In yet another embodiment, the layers  14 ,  16  are not connected together at the inflation side edge. 
     A plurality of longitudinally spaced, transverse seals  22  join the top and bottom layers  14 ,  16 . Referring to  FIGS. 1 and 2 , the transverse seals  22  extend from the seal edge  18  to within a short distance of the inflation edge  20  to form pouches  26 . An optional pocket  23  is formed between the transverse seals  22  and the inflation edge  20 . A pocket is not formed if the inflation edges of the layers  14 ,  16  are not connected. A line of perforations  24  extends through the top and bottom layers.  FIG. 2A  illustrates a length of the web  10  after it has been inflated and sealed to form inflated cushions  12 . An inflation seal  42 , closes the pouches  26  defined by the transverse seals  22  and the seal side edge  18  to form the inflated cushions. The illustrated inflated cushions  12  include gaps G (see  FIG. 2A ) between each pair of adjacent cushions. A web  10  that is specially constructed to form the gaps G was used in the illustrated embodiment. In other embodiments, a web  10  may be used that does not form the illustrated gaps G (see  FIG. 2A ). 
       FIGS. 1A-1B and 2  schematically illustrate an exemplary embodiment of a machine  50  for converting a preformed web  10  (see  FIG. 1 ) to inflated cushions  12  (see  FIG. 2A ). The machine  50  may take a wide variety of different forms and the inflation, sealing and separation arrangements described below may be in the order/positions described or in any other order/position that facilitates inflation of the web  10 , sealing of the web, and separation of the web from the machine  50 . In the example illustrated by  FIGS. 1A-1B and 2 , the machine  50  includes an inflation arrangement  160 , a sealing arrangement  162 , a clamping arrangement  110  including a compliant material  112 , and a web separation device  158 . In one embodiment, the compliant material  112  is a silicone foam rubber, closed cell material having less than a Shore A hardness. The compliant material  112  may be coated with acrylic adhesive on both sides. In one embodiment, the compliant material  112  is usable up to about 390° F. As illustrated in  FIG. 3 , in one embodiment, it is contemplated that the compliant material  112  has a length  2000  of about 4.38″, a height  2002  of about ¼″, and a thickness  2004  of about 1/16″. 
     The inflation arrangement  160  can take a wide variety of different forms. Any arrangement capable of providing air under increased pressure (above atmosphere) to the pouches  26  can be used. In the illustrated embodiment, the inflation arrangement  160  includes a hollow, longitudinally extending guide pin  56  and a blower  60 . Referring to  FIG. 2 , a web  10  is routed from a supply and the pocket  23  is placed around the guide pin  56 , such that the guide pin  56  is between the inflation side edge  20  and the transverse seals  22 . The guide pin  56  aligns the web as it is pulled through the machine  50 . The guide pin  56  includes an inflation opening  102  that is fluidly connected to the blower  60  by a conduit  104 . The blower  60  inflates the web pouches  26  as the web moves past the inflation opening  102 . 
     In an exemplary embodiment, the inflation arrangement  160  also includes a blower control  106 . The blower control  106  can take a wide variety of different focus. For example, the blower control  106  can be any arrangement that is operable to control the flow rate and/or pressure of air provided by the inflation arrangement  160  to the pouches  26 . In one embodiment, the blower control  106  is a speed controller that controls the operation speed of the blower  60 . Such a speed controller speeds the blower up to provide air at higher pressures and/or flow rates and reduces the blower speed to reduce the pressure and/or flow rate. In another embodiment, the blower control  106  comprises a flow control valve in the conduit  104  between the blower  60  and the inflation opening  102 . The conduit  104  may be short as illustrated by  FIG. 1B  or long as illustrated by  FIG. 1A . The conduit may perform or be adapted to perform the function of the web separation device  158 . 
     The sealing arrangement  162  forms the seal  42  ( FIG. 2 ) to create sealed inflated cushions  12 . The sealing arrangement  162  can take a wide variety of different forms. For example, the sealing arrangement  162  can be any arrangement capable of forming a hermetic seal between the layers  14 ,  16 . Referring to  FIG. 1B , the sealing arrangement  162  includes a heated sealing element  64 , a temperature control arrangement  165 , an assembly positioning device  66 , the compliant material  112 , a pair of drive rollers  68 , a belt speed control  67 , and a pair of drive belts  70 . The belt speed control  67  electronically communicates with an encoder  80  to control the speed of the belts  70 . For example, based on a feedback loop, the encoder determines the relative speeds of the belts  70 . If the relative speeds of the belts  70  are not within a predetermined tolerance, the encoder  80  determines an error has occurred. In one embodiment, if the encoder  80  determines an error occurs, the encoder  80  causes the motors to stop the belts  70 . Although the encoder  80  is illustrated as part of the belt speed control  67 , it is to be understood that other embodiments in which the encoder  80  is separate from the belt speed control  67  are also contemplated. 
     In an alternate embodiment, a pair of cooling elements are provided downstream of the heated sealing element  64 . Each belt  70  is provided around its respective drive roller  68 . Each belt  70  is driven by its respective drive roller  68 . The speed of the drive rollers  68  and belts  70  are controlled by the belt speed control  67 . The belts  70  are in close proximity or engage one another, such that the belts  70  pull the web  10  proximate to the heat sealing element  64 . The seal  42  (see  FIG. 2 ) is formed as the web  10  passes through first the heated sealing elements  64 . 
     The heating element  64  can take a wide variety of different forms. Any arrangement capable of raising the temperature of the layers  14  and/or  16  to a point where the layers will hermetically bond together can be used. For example, the heating element  64  may be a heating wire, ceramic element or other member that provides heat upon the application of power. For example, resistance of the heating element  64  causes the heating element  64  to heat up when voltage is applied across the heating element. In the illustrated embodiment, the heating element  64  is a heating wire having a length between about 1″ to about 12″. It is also contemplated that the heating element  64  is a substantially flat wire having a thickness of about 0.011″. 
     The heating element  64  (wire) also includes at least one low resistance portion  82  and at least one high resistance portion  84 . As illustrated in  FIG. 1B , the heating element  64  (wire) includes two relatively lower resistance portions  82  and one relatively higher resistance portion  84 . In one embodiment, the lower resistance portions  82  are copper or are at least include a copper coating or other low resistance coating to provide for relatively high electrical conductivity and relatively low electrical resistance. The lower resistance portions  82  have substantially no electrical resistance, which results in substantially no heat or heat dissipation along those lower resistance portions  82 . The higher resistance portion  84  includes a material that produces relatively low electrical conductivity and relatively high electrical resistance. Consequently, substantially all of the heat is dissipated along the relatively higher resistance portion  84  of the heating element  64 . 
     In one embodiment, the higher resistance portion  84  is between about 1″ long and about 9″ long. In another embodiment, the higher resistance portion  84  is between about 2″ long and about 8″ long. In another embodiment, the higher resistance portion  84  is between about 3″ long and about 7″ long. In another embodiment, the higher resistance portion  84  is between about 4″ long and about 6″ long. In another embodiment, the higher resistance portion  84  is about 4.5″ long. In the embodiment illustrated in  FIG. 4 , the lower resistance portion  82 , which includes a copper coating, has a width  2010  of about 0.118″ (3.0 mm), a length  2012  of about 7.165″ (182 mm), and a thickness of about 0.006″ (0.15 mm). The higher resistance portion  84 , which does not include a copper coating, has a width  2014  of about 0.110″ (2.8 mm) at a point “A”, a length  2016  of about 4.84″ (123 mm), and a thickness of about 0.006″ (0.15 mm). 
     With reference again to  FIG. 1B , the relatively shorter length of the higher resistance portion  82  provides for greater control of the electrical resistance and temperature (e.g., ±1 degree, 2, 5 or 10 degrees,). For example, in one exemplary embodiment the higher resistance portion is only provided in an area where the seal is being formed. This shorter, higher resistance, portion in only the area where the seal is being formed results in more consistent electrical resistance and temperature control than results over a longer high electrically resistive material that has portions outside the area where the seal is being formed. In addition, the relatively shorter length and more consistent electrical resistance of the higher resistance portion  84  results in faster temperature changes when electrical current is applied and removed from the heating element  64 . The faster temperature changes along the heating element  64  are discussed in more detail below. 
     The assembly positioning device  66  is capable of moving the belt  70  associated with the compliant material  112  away from the belt  70  associated with the heating element  64 . For example, the assembly positioning device  66  may cause the belt  70  associated with the compliant material  112  to move upward and away from the belt  70  associated with the heating element  64 . At times, it is desirable to move the belt  70  associated with the compliant material  112  away from the belt  70  associated with the heating element  64  to position the web between the belts  70 . 
     With further reference to  FIG. 1B , in the illustrated embodiment the temperature control arrangement  165  is coupled to the heating element  64  to control the temperature of the heating element  64 . In this embodiment, the temperature control arrangement  165  is coupled to the low resistance portion  82  of the heating element  64 . However, other embodiments in which the temperature control arrangement  165  is coupled to the high resistance portion  84  of the heating element  64  are also contemplated. 
     The temperature control arrangement  165  may take a wide variety of different forms. Any arrangement capable of controlling the heating element  64  can be used. In one exemplary embodiment, the temperature control arrangement  165  includes a thermocouple. The thermocouple may be coupled to the heating element  64  in a variety of different ways. In one exemplary embodiment, the heating element  64  includes a ceramic member that is encapsulated with the thermocouple. The encapsulation of the ceramic member with the thermocouple provides for very accurate measurement of the temperature of the heating element  64 . The temperature measured by the thermocouple is used to adjust the power (e.g., current, voltage, and/or duty cycle) applied to the heating element  64  and thereby control the temperature of the heating element  64 . 
     In one exemplary embodiment, the current passing through the heating element  64  is used to determine the resistance of the heating element. The resistance of the heating element  64  is, in turn, used to determine the temperature of the heating element  64 . For example, the resistance of the heating element  64  can be calculated based on the current passing through the heating element  64  and the voltage across the heating element. The voltage used in the calculation may be acquired in a wide variety of different ways. For example, the voltage used in the calculation may be the voltage applied by the power supply or the voltage may be directly measured by optional bypass leads  84   a ,  84   b  as illustrated by  FIG. 1B . The current used in the calculation may be acquired in a wide variety of different ways. For example, the current used in the calculation may be measured using a Hall Effect sensor or a low resistance, high precision feedback resistor. In one embodiment, where the current is measured with a Hall Effect Sensor, the temperature control arrangement  165  is a solid state device including a Hall Effect sensor for measuring resistance on the heating element  64 . In another embodiment the current is measured with a low resistance, high precision feedback resistor that is in series with the heating element. For example, the low resistance, high precision feedback resistor may be a 20 mΩ resistor. 
     In another exemplary embodiment, the current applied to the heating element is controlled or held constant and the voltage drop across the heating element  64  is used to determine the resistance of the heating element. The resistance of the heating element  64  is, in turn, used to determine the temperature of the heating element  64 . For example, the resistance of the heating element  64  can be calculated based on the current passing through the heating element  64  and the voltage across the heating element. The voltage used in the calculation may be acquired in a wide variety of different ways. For example, the voltage used in the calculation may be the voltage applied by the power supply or the voltage may be directly measured by optional bypass leads  84   a ,  84   b  as illustrated by  FIG. 1B . The current used in the calculation may be acquired in a wide variety of different ways. For example, the current used in the calculation may be a fixed current applied by the power supply. In this embodiment, the duty cycle of the current can be increased to increase the temperature of the heating element and the duty cycle of the current can be decreased to decrease the temperature of the heating element. 
     In one embodiment, it is contemplated that direct current (DC) is used to power the heating element  64 . Powering the heating element  64  with direct current (DC), as opposed to alternating current (AC), permits the temperature control arrangement  165  to calculate resistance (i.e. as a function of current and voltage) in the heating element  64  (e.g., the high resistance portion  84  of the heating element  64 ). The temperature of the heating element  64  (e.g., high resistance portion  84  of the heating element  64 ) is determined (e.g., calculated or correlated) based on the calculated resistance. Determining the temperature of the heating element  64  based on the calculated resistance provides a relatively faster temperature response than if alternating current (AC) is used to power the heating element  64 . In one embodiment, the DC power is cycled on and off according to a duty cycle to achieve a desired set point temperature of the high resistance portion  84  of the heating element  64 . For example, with respect to  FIG. 5 , a voltage of the DC power is switched between zero (0) volts and 5.5 volts according to a duty cycle to achieve a desired temperature of the heating element  64 . For example, the duty cycle is increased (i.e. more on time) to increase the temperature and the duty cycle is decreased (i.e. more off time) to decrease the temperature. 
     Referring to  FIG. 5A , in another embodiment, which is discussed in more detail below, a voltage of the DC power is controlled to a continuous (e.g., constant) voltage output between, for example, zero (0) volts and 5.5 volts to achieve the desired temperature of the heating element  64 . For example, the DC voltage is increased to increase the temperature and the DC voltage is decreased to decrease the temperature. 
     Once the temperature control arrangement  165  determines the temperature of the heating element  64  (e.g., high resistance portion  84  of the heating element  64 ), the heating element  64  is capable of controlling the power supplied to the heating element  64  for achieving or maintaining a temperature of the high resistance portion  84  of the heating element  64  within a predetermined temperature range. For example, if the temperature of the high resistance portion  84  of the heating element  64  is above the predetermined temperature range, the temperature control arrangement  165  may cause the amount of direct current (DC) supplied to the heating element  64  to be reduced. Conversely, if the temperature of the high resistance portion  84  of the heating element  64  is below the predetermined temperature range, the temperature control arrangement  165  may cause the amount of direct current (DC) supplied to the heating element  64  to be increased. 
       FIG. 1B  illustrates an exemplary embodiment of a clamping arrangement  110  including the compliant material  112 . The clamping arrangement  110  is positioned to pinch the top and bottom layers  14 ,  16  of the preformed web  10  together. The clamping arrangement  110  inhibits air under pressure P ( FIG. 2 ) in the inflated webs from applying force to the molten longitudinal seal  42 . This prevents the air under pressure P from blowing the molten longitudinal seal  42  open and/or creating undesirable stresses that weaken the longitudinal seal. 
     The clamping arrangement  110  can take a wide variety of different forms. For example, the clamping arrangement  110  can be any arrangement capable of squeezing the layers  14 ,  16  in an area where the material of the layers is molten, soft or not yet completely solidified and cool. In the illustrated embodiment of  FIG. 1B , the clamping arrangement  110  includes a pair of drive rollers  68 , a pair of drive belts  70 , the compliant material  112 , and an optional assembly positioning device  66 . Each belt  70  is disposed around its respective drive roller  68 . Each belt  70  is driven by its respective drive roller  68 . The drive rollers  68  may be coupled to the drive rollers  68  (see  FIG. 1B ) of the heat sealing belts  70  (see  FIG. 1B ) or the drive rollers  68  may be driven independently of the drive rollers  68  (see  FIG. 1B ). The belts  70  engage one another, such that the belts  70  pull the web  10  and pinch the web as the web passes by the heat sealing element  64  and the compliant material  112 . Another exemplary clamping arrangement is disclosed by U.S. Pat. No. 7,571,584, which is incorporated herein by reference in its entirety. 
     In the illustrated embodiment, the compliant material  112  is on an opposite side of the belt  70  than the web  10 . As the web passes by the heat sealing element  64  and the compliant material  112 , the compliant material acts to keep substantially constant pressure on the web while the web passes by the heat sealing element  64 . For example, the compliant material  112  is a material having a spongy and/or rubbery characteristic. Therefore, as the web passes by the compliant material  112 , imperfections in the web (e.g., wrinkles) are reduced since the spongy and/or rubbery compliant material  112  can slightly deform as the imperfections pass by the compliant material  112 . In other words, the “forgiving” nature of the compliant material  112  results in the substantially constant pressure on the web as the web passes by the heat sealing element  64 . The substantially constant pressure on the web results in a better seal. 
     It is contemplated that the compliant material  112  is at least as long as the high resistance portion  84  of the heat sealing element  64 . However, the compliant material  112  may be longer as illustrated, for example, at least twice or even three times, or more as long, as illustrated by  FIG. 18 . 
     Referring to  FIG. 2 , the web separation device  158  can take a wide variety of different forms. For example, when the web  10  includes a line of perforations at or along the seal side edge  18 , the web separation device  158  may be a blunt surface, when the inflation edge  20  is not perforated the separation device  158  may be a sharp knife edge, and when the layers  14 ,  16  are not connected together at the seal side edge the web separation device may be omitted. In the illustrated embodiment, the web separation device  158  is positioned along the path of travel of the web prior to the heat sealing element  64 . The web separation device  158  is positioned prior to the heat sealing element  64  so that the web separation device opens the pocket  23  of the web at the same time the pouches  26  are being sealed. However, the web separation device  158  can be positioned anywhere along the path of travel of the web. For example, the web separation device  158  can be positioned before the sealing arrangement  162 , after the sealing arrangement, before the inflation opening  102 , or after the inflation opening  102 . The illustrated separation device  158  extends from the pin  56 . However, the separation device  158  may be mounted to the machine  50  in any manner. The separation device  158  opens the web  10  at or near the inflation side edge  20  as the web moves through the machine  50 . 
       FIG. 6  illustrates an exemplary embodiment of a control algorithm  300  for the inflation machine  50 . In the illustrated embodiment, the control algorithm  300  includes an off state  302 , an idle sequence  304 , a start sequence  306 , a run sequence  308 , and a stop sequence  310 . In the off state, the inflation arrangement  160  and the sealing arrangement  162  are both turned off. 
       FIG. 7A  illustrates the idle sequence  304  and  FIGS. 7B-7C  illustrate the states of the components of the machine  50  when the machine executes the idle sequence.  FIGS. 7B and 7C  illustrate an exemplary embodiment where the sealing arrangement  110  illustrated by  FIGS. 1A and 1B  is idle. When the machine  50  is turned on  400 , the machine begins the idle sequence  304 . In the idle sequence  304 , the sealing element  64  is set  402  to an idle temperature by the temperature control arrangement  165 . The inflation arrangement  160  is set  404  to an idle output or speed by the inflation control  106 . Referring to  FIG. 7C , in an exemplary embodiment, the belt speed control  67  stops the belts  70 ,  70  and the positioning device  66  positions the belt  70  to either separate from or connect to the web  10 . As such, when the machine  50  executes the idle sequence  304 , the inflation arrangement  160  pre-inflates the pouches  26  and the heating element  64  is pre-heated, but spaced apart from the web. This pre-inflation and pre-heating reduces the time it takes for the machine  10  to transition to production of inflated cushioning members. In one exemplary embodiment, the web is pre-inflated, but the heating element  84  is not preheated. For example, when the heating element  84  is short and has a fast response time, the heating element heats up very quickly and does not need to be preheated in the idle sequence of  FIG. 7A . 
       FIG. 8A  illustrates the start sequence  306  and  FIGS. 8B-8E  illustrate the states of the components as the machine  50  executes the start sequence. When the machine  50  is turned  420  ( FIG. 7A ) from the idle sequence  304  to the start sequence  306 , the machine  50  optionally identifies  500  the type of material being inflated and sealed. For example, the machine may determine that that the material is a pillow type material (see for example FIG.  1 ) or a wrap type material (see for example U.S. Pat. Nos. D633792 and D630945). The machine may also optionally determine the size and type of material the web  10  is made from in this step. 
     In the start sequence  304 , the sealing elements  64  are raised from the idle temperature to a sealing temperature (when the sealing temperature is higher than the idle temperature or when the sealing elements are not pre-heated) by the temperature control arrangement  165  at steps  502  and  504 . At step  506 , the inflation arrangement  160  is optionally ramped up  508  from the idle output or speed to the inflation output or speed. The ramp up from the idle output or speed to the inflation output or speed may be controlled in a variety of different ways. For example, the inflation arrangement may be ramped up until an inflation pressure set point in the web  10  is reached, until the inflation device reaches a speed set point, and/or until a predetermined period of time has elapsed after the inflation device reaches a speed set point. 
     In the exemplary embodiment, the machine closes (See  FIG. 8E ) the sealing element  64  at steps  512  and  514 , when the machine is not already closed. Very little or no material is wasted upon start up of the machine. That is, the first pouches  26  that are fed into the machine  50  are inflated and sealed, rather than being un-inflated or under-inflated. 
     In the exemplary embodiment, the machine optionally determines  520  whether the inflation arrangement  160  has already been ramped to the inflation speed or output after the sealing element has closed on the web  10 . Once the sealing element  64  is closed on the web  10 , the belt speed control  67  starts  524  the belts  70 ,  70  (see arrows in  FIG. 8E ) and the machine begins producing sealed and inflated cushions and moves on  525  to the run sequence. 
     In one exemplary embodiment, control of the sealing arrangement  162 , inflation arrangement  160 , and/or the drive rollers  68  are interrelated. For example, the sealing arrangement  162 , inflation arrangement  160 , and/or the drive rollers  68  are controlled based on input from one or more of the temperature control arrangement  165 , belt speed control  67  and/or the blower control  106 . By interrelating the sealing arrangement  162 , inflation arrangement  160 , and/or the drive rollers  68 , the air/pressure in the pouches and/or the quality of the inflation seal  41 , may be precisely controlled. 
     In an exemplary embodiment, the belt speed may be controlled based on feedback from the encoder  80 , the blower control  106  and/or the temperature control arrangement  165 . If the temperature of the sealing element  64  is lower than a predetermined set point, the belt speed may be reduced to ensure that enough heat is applied to the web to form a high quality seal. Similarly, if the temperature of the sealing element  64  is higher than a predetermined set point, the belt speed may be increased to ensure that too much heat is not applied to the web and thereby ensure that a high quality seal is formed. If the output or speed of the inflation arrangement  160  is lower than a predetermined set point, the belt speed may be reduced to ensure that the pouches  26  are optimally filled. In an exemplary embodiment, the encoder  80 , the blower output or speed and/or the heating element temperature  64  are continuously controlled to bring the blower output or speed and the heating element temperature to predetermined set points. The speed of the belts may be continuously updated based on the feedback from the blower control  106  and/or the temperature control arrangement  165  to optimize the seal quality and pouch filling, especially as the inflation arrangement and/or the sealing element are being ramped to their normal operating conditions. 
     In an exemplary embodiment, the temperature of the sealing element  64  may be controlled based on feedback from the encoder  80 , the inflation control  106  and/or the belt speed control  67 . If the belt speed is lower than a predetermined set point, the temperature of the sealing element  64  may be reduced to ensure that too much heat is not applied to the web and ensure that a high quality seal is formed. Similarly, if the belt speed is higher than a predetermined set point, the temperature of the sealing element  64  may be increased to ensure that enough heat is applied to the web and a high quality seal is formed. In an exemplary embodiment, the encoder  80 , the blower output or speed and/or the belt speed control  67  are continuously controlled to bring the blower output or speed and the belt speed to predetermined set points. The temperature of the sealing element  64  may be continuously updated based on the feedback from the blower control  106  and/or the belt speed to optimize the seal quality and pouch filling, especially as the inflation arrangement and/or the belt speed are being ramped to their normal operating conditions. 
     In an exemplary embodiment, the inflation arrangement  160  may be controlled based on feedback from the encoder  80 , the belt speed control  67  and/or the temperature control arrangement  165 . If the temperature of the sealing element  64  is lower than a predetermined set point, the blower output or speed may be changed to ensure proper inflation and sealing of the air filled cushions. If the belt speed is lower than a predetermined set point, the blower output or speed may be changed to ensure proper inflation and sealing of the air filled cushions. In an exemplary embodiment, the belt speed and/or the heating element temperature are continuously controlled to bring the belt speed and/or the heating element temperature to predetermined set points. The blower speed or output may be continuously updated based on the feedback from the encoder  80 , the drive roller control  67  and/or the temperature control arrangement  165  to optimize the seal quality and pouch filling, especially as the belt speed and/or the sealing temperature are being ramped to their normal operating conditions. 
     In one exemplary embodiment, the temperature of the sealing arrangement  162  is independent of feedback from inflation control and belt control. In this embodiment, belt speed may be controlled based solely on feedback from the sealing arrangement  162 . Similarly, in this embodiment, the inflation arrangement  162  may be controlled based solely on feedback from the sealing arrangement  162 . In an exemplary embodiment, the machine  50  is programmed with a control loop that brings the sealing arrangement  162  to a temperature set point and to hold the temperature at the set point. During execution of this control loop, the current temperature of the sealing arrangement is monitored and is used to control the belt speed and inflation arrangement  162 . 
       FIG. 9  illustrates an exemplary embodiment of a run sequence  308  where control of the sealing arrangement  162 , inflation arrangement  160 , and/or the drive rollers  68  are interrelated. It should be appreciated that the control of the sealing arrangement  162 , inflation arrangement  160 , and/or the drive rollers  68  can be interrelated in a wide variety of different ways and that  FIG. 9  illustrates one of the many possibilities. In  FIG. 9 , relationships of the belt speed and inflation device speed or output with respect to the temperature of the heating device are set  600 . The belt speed and inflation device speed or output are set  602  based on the current temperature of the sealing element  64 . In another embodiment, where the response time of the sealing element is fast, the temperature of the sealing element may be set based on the belt speed and/or the inflation device speed. In the illustrated example, the belt speed and inflation device speed or output are set  602  based on the current temperature of the sealing element  64 . At optional step  604 , if the set point of the sealing element  64  and/or the set point of the inflation arrangement  160  have changed (for example, due to user input), the updated set points are retrieved  606  and the relationships of the belt speed and inflation device speed or output with respect to the temperature of the heating device are reset  600 . If the set point of the sealing element  64  and/or the set point of the inflation arrangement  160  have not changed, the sequence checks  608  to see if the sealing element  64  has reached the temperature set point. If the sealing element  64  has not reached the temperature set point, the belt speed and inflation device speed or output are updated  602  based on the current temperature of the sealing element  64 . This process is repeated until the sealing element  64  reaches the temperature set point. 
     Once the sealing element  64  is at the temperature setting  610  and the belt speed and inflation device output are at the corresponding set points  612 , the encoder  80  ensures the relationships between the belt speed and inflation device speed are maintained. Alternatively, in other embodiments, the relationships between the belt speed and inflation device speed or output with respect to the temperature of the heating device may optionally be disregarded  614  until the machine is stopped or for a predetermined period of time or until an event is detected that triggers updating of the belt speed and/or inflation device output. At this point, the machine  50  is running at a full or optimal speed  615  and continues to do so until an inflation setting changes  616 , a heat setting changes  618 , or the machine is stopped  620 . When an inflation device setting changes, the inflation device speed or output is increased or decreased  622  based on the new setting. When a temperature setting changes, the heating device temperature set point is increased or decreased  624  based on the new setting. When the machine is stopped, the sequence proceeds  626  to the stop sequence  310 . 
       FIG. 10A  illustrates an exemplary stop sequence and  FIGS. 10B-10C  illustrate examples of conditions of components of the machine  50  during the stop sequence. In the stop sequence  310 , the belt speed control  67  stops  700  the belts  70 ,  70  ( FIG. 7C ). At optional step  702 , if the material is pillow type material, the inflation arrangement  160  is braked  703 . At step  704 , the sequence optionally confirms that the belts  70  have been stopped. Once the belts  70  are stopped, the machine optionally opens  706  the sealing element  64 . At optional step  708 , if the material is wrap type material, the sequence allows  710  a predetermined period of time to elapse and then the inflation arrangement  160  is braked  712 . At step  714 , the sequence confirms  716  that both the belts  70  and the inflation arrangement  160  are stopped and the sequence optionally returns to the idle sequence  304  or the stop state  302 . 
     With reference to  FIG. 11 , in one embodiment, alternating current (AC) power is supplied to an alternating current to direct current (DC) converter (AC/DC converter)  3000 . The AC/DC converter  3000  provides DC power to, for example, motors  88  (see  FIG. 13 ) that drive the belts  70  (see  FIG. 1B ), the blower  60 , and a DC/DC converter  3004 . The DC power supplied to the motors, blower, and/or the DC/DC converter can be any appropriate DC voltage, such as 12V, 24V, or 48V. In one embodiment, the DC/DC converter  3004  receives the DC power from the AC/DC converter  3000  and is programmable to provide a DC power output that is adjustable between zero (0) volts and an appropriate maximum DC voltage for the heating element  64 , such as, for example 5.5 Volts DC. It is contemplated that the DC power output between zero (0) volts and the maximum DC voltage is a continuous analog DC output that is quickly adjustable to control the temperature of the heating element  64 . In another embodiment, the DC/DC converter  3004  receives is programmable to provide a DC power output having a current output that is adjustable to control the temperature of the heating element  64 . 
     The DC power output of the DC/DC converter  3004  may be used to control the heater temperature control  165  (see  FIG. 1B ). In one embodiment, the DC power output of the DC/DC converter  3004  is included in a control loop with the heater temperature control  165  for controlling the temperature of the heating element  64 . In one exemplary embodiment, the output voltage of the DC/DC converter is increased to increase the temperature of the heating element  64  or decreased to decrease the temperature of the heating element  64 . In another exemplary embodiment, the output current of the DC/DC converter is increased to increase the temperature of the heating element  64  or decreased to decrease the temperature of the heating element  64 . 
     In one embodiment, the heater temperature control  165  (see  FIG. 1B ) receives a desired set point temperature from, for example, a user input  3006  (see  FIG. 1B ) such as a knob or switch that may be included on the heater temperature control  165 . Alternatively, the heater temperature control  165  receives the desired set point temperature from an external computing device. The heater temperature control  165  electronically communicates a signal to the DC/DC converter  3004  based on a current temperature of the heating element  64  (see  FIG. 1B ) and the set point temperature. In one embodiment, the current temperature of the high resistance portion  84  (see  FIG. 1B ) of the heating element  64  (see  FIG. 1B ) is determined based on a calculated resistance of the high resistance portion as described above. For example, voltage measurements may be obtained at the ends  84   a ,  84   b  (see  FIG. 1B ) of the high resistance portion  84  (see  FIG. 1B ) or by using the voltage applied by the DC/DC converter  3004 . Then, the current through the high resistance portion  84  (see  FIG. 1B ) is measured, for example with a Hall Effect sensor or a low resistance, high precision feedback resistor as described above. The resistance is determined based on the voltage and the current according to the equation Resistance (R)=Voltage (V)/Current (I). 
     If, for example, the set point temperature is 300° F. and the current temperature of the heating element  64  (see  FIG. 1B ) is determined to be 280° F., the heater temperature control  165  (see  FIG. 1B ) electronically communicates a signal to the DC/DC converter  3004  to increase the DC voltage output of the DC/DC converter  3004  which, in turn, increases the resistance of the high resistance portion  84  (see  FIG. 1B ) of the heating element  64  (see  FIG. 1B ). Since the temperature of the high resistance portion  84  (see  FIG. 1B ) of the heating element  64  (see  FIG. 1B ) is related to the resistance of the high resistance portion  84  (see  FIG. 1B ), changing the resistance of the high resistance portion  84  (see  FIG. 1B ) correspondingly changes the temperature of the high resistance portion  84  (see  FIG. 1B ). It is contemplated that the temperature of the heating element is measured and calculated very often. In one exemplary embodiment, the temperature of the heating element is measured and calculated at more than 100 Hz, such as at about 281 Hz. As such, the heated sealing element  64  is monitored every 10 ms or less, 5 ms or less, 2 ms or less, or 1 ms or less, instead of about every 20 ms if the system uses AC power operated at 50 Hz and sampling is done on full waves. This allows for very precise control of the temperature of the heating element, such as between 1° F. and 5° F. 
     It is contemplated that the signal communicated to the DC/DC converter  3004  is based on the level of temperature changed (e.g., resistance change) desired to achieve the set point temperature of the heating element  64  (see  FIG. 1B ). For example, if it is desired to raise the temperature of the heating element  64  to achieve the set point temperature by only 10° F., the signal communicated to the DC/DC converter  3004  will cause the DC/DC converter  3004  to change the DC voltage output a relatively smaller amount than if it is desired to raise the temperature of the heating element  64  (see  FIG. 1B ) by 50° F. In other words, the signal communicated to the DC/DC converter  3004  will cause the DC/DC converter  3004  to change the DC voltage output proportionally according to the level of resistance change (e.g., temperature change) needed to bring the temperature of the heating element  64  (see  FIG. 1B ) to the set point temperature. In that regard, if it is desired to raise the temperature of the heating element  64  (see  FIG. 1B ) to achieve the set point temperature, the signal communicated to the DC/DC converter  3004  will cause the DC/DC converter  3004  to increase the DC voltage output, while if it is desired to lower the temperature of the heating element  64  (see  FIG. 1B ) to achieve the set point temperature, the signal communicated to the DC/DC converter  3004  will cause the DC/DC converter  3004  to lower the DC voltage output. 
     In the embodiment discussed above, the resistance is changed to achieve a desired temperature change of the high resistance portion  84  (see  FIG. 1B ) of the heating element  64  (see  FIG. 1B ). Alternatively, a thermocouple is provided to directly measure the temperature of the high resistance portion  84  (see  FIG. 1B ) of the heating element  64  (see  FIG. 1B ). 
     With reference to  FIG. 12 , in another embodiment, alternating current (AC) power is supplied to two alternating current to direct current (DC) converters (AC/DC converters)  3010 ,  3012 . The first of the AC/DC converters  3010  provides DC power (e.g., a fixed DC voltage) to, for example, motors  88  (see  FIG. 13 ) that drive the belts  70  (see  FIG. 1B ), and the blower  60 . Any appropriate DC voltage for the motors  88  and blower  60  may be selected. For example, this DC voltage may be 12V, 24V, or 48V. The second of the AC/DC converters  3012  is programmable to provide an adjustable DC power output between zero (0) volts and an appropriate maximum DC voltage for the heating element  64 , such as 5.5 Volts DC. However, any maximum DC voltage may be selected (as long as it is high enough to achieve the maximum temperature of the heating element), since the output is adjustable. It is contemplated that the DC power output between zero (0) volts and the maximum DC voltage is a continuous analog DC output and is quickly adjustable to control the temperature of the heating element. The output DC voltage of the AC/DC converter is increased to increase the temperature of the heating element  64  or decreased to decrease the temperature of the heating element  64 . 
     The machine  50  may take a wide variety of different forms.  FIGS. 13, 13A, 15A, 18, 19, 31, and 32  and  FIGS. 14, 14A, 16, 17, 20, and 21  illustrate two non-limiting, exemplary embodiments of the machine  50  in detail. In the example illustrated by  FIGS. 13, 13A, 15A, 18, 19, 31, and 32 , the machine  50  includes an inflation arrangement  102 , and a sealing arrangement  110 .  FIG. 13  illustrates the machine  50  with a cover  802  disposed over the sealing arrangement  110 .  FIG. 13A  illustrate the machine  50  with the cover removed. 
     Referring to  FIGS. 13, 13A, 15A, 18, 19, 31, and 32 , the web  10  is routed from a supply to and around a pair of elongated, transversely extending guide rolls  854 . The web  10  is then routed to a longitudinally extending guide pin  856 . The guide pin  856  is disposed between the inflation edge  20  and the transverse seals  22  of the web  10 . The guide pin  856  aligns the web as it is pulled through the machine. 
     The inflation arrangement  110  can take a wide variety of different forms. Referring to  FIG. 18 , in the illustrated embodiment, the inflation arrangement  110  includes the hollow, longitudinally extending guide pin  856 . The blower and blower control are disposed in a housing  1204  ( FIG. 13 ) of the machine  50 . 
     With reference to  FIG. 13A , the web  10  passes from the guide rolls  854  to the pin  856  and the separation device  158  before passing into the sealing and clamping arrangement  110 . With reference to  FIG. 14A , the machine  50  includes the encoder  80  to measure the web  10  travel and encoders  81  to measure the operating speeds the motors. With reference to  FIG. 15A , the encoder  80  is illustrated before the separation device  158  and the sealing and clamping arrangement  110 . With reference to  FIGS. 18 and 19 , the encoders  81  are illustrated as separate from the motors  88 , but may be part of the motor assemblies. 
     With reference to  FIG. 31 , the machine  50  is illustrated showing the guide pin  56 , the separation device  158 , and the sealing and clamping arrangement  110 .  FIG. 32  illustrates a cross-sectional view of the machine  50  along the B-B in  FIG. 31 . With reference to  FIG. 32 , the heated sealing element  64  and compliant material  112  are illustrated in the sealing and clamping arrangement of the machine  50 . 
       FIGS. 14, 14A, 16, 17, 17A, 17B, and 20-30  illustrate a second non-limiting, exemplary embodiment of an inflation machine  50  in detail. In the example illustrated by  FIGS. 14, 15, 16, 17, 17A, 17B, and 20-30 , the machine  50  includes an inflation arrangement  960  (see  FIG. 17 ), a sealing arrangement  962  (see  FIG. 20 ), a clamping arrangement  910 , and a web tensioning device  875  (see  FIG. 17 ). 
     Referring to  FIG. 14 , the web  10  is routed from a supply to and around a pair of elongated, transversely extending guide rollers  854 . The web  10  is then routed to a longitudinally extending guide pin  856 . The guide pin  856  is disposed between the inflation edge  20  and the transverse seals  22  of the web  10 . The guide pin  856  aligns the web as it is pulled through the machine. The web  10  is routed along the guide pin  856  through the web tensioning device  875 . 
     The tensioning device  875  keeps the web  10  (see  FIG. 17B ) taught as the web is pulled through the machine  50  (see  FIG. 17 ). Keeping the web taught in the sealing arrangement  962  prevents wrinkles from forming in the seal  23 . The tensioning device can take a wide variety of different forms. Any arrangement that applies tension to the web  10  can be used. Referring to  FIGS. 17A and 17B , in the illustrated embodiment the tensioning device  875  includes a roller  877 , a spring loaded pivot arm  879 , and a shelf member  881 . The shelf member  881  is fixed with respect to the path of travel of the web  10 . The illustrated shelf member  881  includes a substantially horizontal portion  883  and an upwardly extending portion  885  that extends upward at an obtuse angle from the substantially horizontal portion  883 . 
     The substantially horizontal portion  883  and the upwardly extending portion  885  can take a variety of different forms. In  FIG. 17A , a centerline  1252  (the midpoint between the top and the bottom) of the guide pin  856  is depicted. In an exemplary embodiment, an upper surface  1260  of the substantially horizontal portion  883  is lower than the centerline  1252 . In the example illustrated by  FIG. 17A , an upper surface  1260  of the substantially horizontal portion  883  is lower than a bottom  1262  of the guide pin  856 . In  FIG. 17A , a horizontal line  1250  that is tangent to the top or uppermost surface of the upwardly extending portion  885  is depicted. In an exemplary embodiment, the top or uppermost surface  1250  is positioned to keep the pocket  23  taught against the guide pin  856 , but not so taught that the perforations of the pocket  23  break. By pulling the pocket  23  of the web  10  taught against the guide pin  856 , wrinkles in the web are eliminated as the web passes through the sealing arrangement  162 . In one exemplary embodiment, the uppermost surface  1250  is positioned at or above the centerline  1252  of the guide pin  856 . For example, the uppermost surface  1250  may be positioned at a distance D above the centerline. The distance D may be less than or equal to 0.250 inches, less than or equal to 0.218 inches, less than or equal to 0.187 inches, less than or equal to 0.156 inches, less than or equal to 0.125 inches, less than or equal to 0.093 inches, less than or equal to 0.062 inches, or less than or equal to 0.031 inches. 
     Referring to  FIG. 17B , the pivot arm  879  is pivotally mounted to the machine  50  at a pivot  887 . A spring  889  is attached to a first end of the pivot arm and to the machine  50 . The roller  877  is rotatably attached to the second end of the pivot arm  879 . The spring  889  forces the roller  877  against the shelf member  881  at the intersection of the substantially horizontal portion  883  and the upwardly extending portion  885 . It should be readily apparent that the roller  877 , the pivot arm  879  and/or the spring  889  can be replaced with any arrangement that frictionally engages the web. The frictional force is selected to keep the web  10  taught as the web passes through the sealing arrangement  162 , but the frictional force is not great enough to cause the web  10  to tear. In one exemplary embodiment, the force applied between the roller  877  and the shelf  881  is between 5 lbs and 10 lbs, such as about 7 lbs or 7 lbs. The width of the contact area between the roller  877  and the shelf member  881  also influences the frictional force applied to the web  10 . In one exemplary embodiment, the width of the contact area between the roller  877  and the shelf member  881  is between 0.062 and 0.375 inches, between 0.093 and 0.250 inches, between 0.125 and 0.187 inches, about 0.140 inches, or 0.140 inches. 
     Referring to  FIG. 17B , the web  10  is routed between the roller  877  and the shelf member  881  such that the roller and the shelf member frictionally engage the layers  14 ,  16  of the web  10 . The web  10  passes under the roller  877 , up and over the upwardly extending portion  885  of the shelf member, and then into the sealing arrangement  962 . The friction between the web  10 , the roller  877 , and the shelf member  881  keeps the web taught as the web is pulled through the sealing arrangement  962 . 
     The inflation arrangement  960  can take a wide variety of different forms. Referring to  FIG. 17 , in the illustrated embodiment, the inflation arrangement  960  includes the hollow, longitudinally extending guide pin  856  and an inlet opening  1200  for fluid connection to a blower or other source of air under pressure or other fluid under pressure. The illustrated guide pin  856  includes a plurality of inflation openings  1202 . The inflation openings  1202  can take a wide variety of different forms. In the illustrated embodiment, the guide pin  856  includes a first, relatively large, opening  1200  and a plurality of smaller openings  1202 . The illustrated opening  1200  is a slot with semi-circular ends. The illustrated smaller openings  1202  are circular in shape. The blower and blower control are disposed in a housing  1204  ( FIG. 14 ) of the machine  50 . 
     The sealing arrangement  962  forms the seal  42  to create sealed inflated cushions  12 . The sealing arrangement  962  can take a wide variety of different forms. Referring to  FIGS. 20-22 , the sealing assembly  962  includes a compliant material  864  and a heated sealing element  865 , a positioning device  866 , drive rollers  868 , idler rollers  869 , and sealing belts  870 . Each belt  870  is disposed around its respective heat sealing elements  864 ,  865 , drive roller  868 , and idler rollers  869 . Each belt  870  is driven by its respective drive roller  868 . In an exemplary embodiment, the speed of the drive rollers  868  and belts  870  are controlled by a belt speed control that is disposed in the housing  1204  of the machine. The belt speed control may be part of an overall controller for the machine or the belt speed controller may be a separate device that interfaces with other devices. The belts  870  engage one another, such that the belts  870  pull the web  10  through the heat sealing elements  864 ,  865 . The seal  42  is formed as the web  10  passes through the heated sealing elements  864 ,  865 . 
     Referring to  FIG. 26 , in the illustrated example the heat sealing element  864  is biased toward the heat sealing element  865  by a biasing assembly  2100 . The biasing assembly  2100  can take a wide variety of different forms. The biasing arrangement may be any arrangement that biases the heat sealing elements  864 ,  865  relatively toward one another. In the illustrated example, the biasing assembly  2100  includes a support member  2101 , a shaft member  2102 , a spring  2104  disposed around the shaft member, and a coupling member  2106  connected to the heat sealing element  864 . A head  2108  of the shaft member  2102  is disposed in a counterbore  2110  of the support member  2101  with a shaft portion  2112  of the shaft member extending through a hole  2114  in the support member  2101 . The shaft member  2102  is free to move axially in the counterbore. An end of the shaft portion is connected to the coupling member  2106 . The spring  2104  pushes the coupling member  2106  and attached heat sealing element  864  downward. The biasing assembly  2100  ensures that the heat sealing elements  864 ,  865  securely engage the web  10  between the belts  1070  whenever the belts are engaged. 
     The heating element  864  can take a wide variety of different forms. Referring to  FIG. 26 , in the illustrated example the heating element  864  includes an outer body  1600 , an internal ceramic element  1602 , and an internal thermocouple  1604  or other device for measuring the temperature of the internal ceramic element  1602 . A potting material or other encapsulating material surrounds the internal ceramic element  1602  and the thermocouple  1604 . In an exemplary embodiment, the thermocouple  1604  is disposed directly on the ceramic element  1602 . As discussed above, in other embodiments the heating element  864  may also be the wire including at least one low resistance portion  82  and at least one high resistance portion  84 . The compliant material  112  is included as part of a spring loaded clamping assembly  1800 , which is discussed below. 
     A temperature control arrangement is coupled to the thermocouple  1602  and the ceramic element  1602  for controlling the temperature of the ceramic element  1602  based on feedback from the thermocouple  1604 . The temperature measured by the thermocouple is used to adjust the power applied to the heating element and thereby control the temperature of the heating element. The temperature control arrangement is disposed in the housing  1204  of the machine. The temperature control arrangement may be part of an overall controller for the machine or the temperature control arrangement may be a separate device that interfaces with other devices. 
     The heating sealing element positioning device  866  can take a wide variety of different forms. Referring to  FIGS. 26 and 27 , in the illustrated example the heat sealing element  865  is coupled to the upper support members  2101  and a lower support member  2103 . The heat sealing element  865  is fixed to the lower support member  2103 . However, the lower heat sealing element may be coupled to the lower support member  2103  in any manner. For example, the lower heat sealing element  865  may be coupled to the lower support member  2103  by a second biasing assembly. In the illustrated embodiment, the heat sealing element positioning device  866  (see  FIG. 25 ) comprises two upper actuators  1300 ,  1302  (see  FIG. 22 ) and two lower actuators  1304 ,  1306  (see  FIG. 22 ). The two upper actuators  1300 ,  1302  (see  FIG. 22 ) are each operably connected to the upper support member  2101  and a fixed component of the machine  50 , such as the housing  1204 . The two lower actuators  1304 ,  1306  are each operably connected to the lower support member  2103  and a fixed component of the machine  50 , such as the housing  1204 . The actuators  1300 ,  1302 ,  1304 ,  1306  are operable to move the upper and lower support members  2101 ,  2103  and coupled heat sealing element  865  relatively toward and away from one another. As such, the heating element  865  is positioned with respect to the path of travel of the web  10  such that the sealing belts  870  selectively engage and disengage the web  10 . 
     Referring to  FIGS. 29 and 30 , the illustrated upper and lower support members  2101 ,  2103  include seal cooling portions  2401 ,  2403 . The seal cooling portions  2401 ,  2403  engage the belts  870  and compress the material of the seal downstream of the sealing elements  864 ,  865 . Heat of the seal is transferred through the belts  870  and into the seal cooling portions  2401 ,  2403  of the support members  2101 ,  2103  to cool the material of the seal. The illustrated upper and lower support members  2101 ,  2103  include optional holes  2410 . The holes  2410  increase the surface area of the upper and lower support members  2101 ,  2103  to increase their effectiveness as heat sinks and reduce their weight. The upper and lower support members  2101 ,  2103  can be made from a wide variety of different materials. In an exemplary embodiment, the support members are made from a thermally conductive material such as aluminum or copper. 
     The clamping arrangement  910  is positioned to pinch the top and bottom layers  14 ,  16  of the preformed web together. The clamping arrangement  910  can take a wide variety of different forms. Referring to  FIGS. 23 and 24 , the clamping arrangement  910  includes drive rollers  1068 , idler rollers  1069 , spring loaded clamping assemblies  1800 , a clamping portion  1802  of the lower support member  2103 , and a pair of drive belts  1070 . The illustrated clamping portion  1802  of the lower support member  2103  includes a support surface  1810  or groove and a lip  1812 . The width of the support surface  1810  or groove corresponds to the width of the belts  1070 . The support surface  1810  supports the lower belt  1070  and the lip  1812  retains the belt or the support surface. 
     Referring to  FIGS. 29 and 30 , each spring loaded clamping assembly  1800  includes a clamping member  1900 , a shaft member  1902 , and a spring  1904  disposed around the shaft member. The clamping members  1900 , shaft members  1902 , and springs are coupled to a support member  1901 . Each clamping member  1900  is biased toward the clamping portion  1802  of the lower support portion  2103  by the springs  1902 . A head  1908  of each shaft member  1902  is disposed on the support member  1901  with a shaft portion  1912  of the shaft member extending through a hole  1914  in the support member  1901 . The shaft member  1902  is free to move axially in the counterbore. An end of each shaft portion  1912  is connected to a clamping member  1900 . The springs  1904  push the clamping members  1900  downward. The biasing assemblies  1800  ensure that the belts  1070  securely engage the web  10  whenever the belts are engaged. 
     Each belt  1070  is disposed around its respective drive rollers  1068  and idler rollers  1069 . Each belt  1070  is driven by its respective drive roller  1068 , which is attached to a drive roller  868 . As such, the sealing belts  870  and the pinching belts  1070  are driven in sync. The belts  1070  engage one another, such that the belts  1070  pull the web  10  and pinch the web as the web moves through the heat sealing element  865 . 
       FIG. 33  illustrates a component diagram of a system  90  including the machine  50 . The system  90  includes the rollers  68 , belts  70 , the heated sealing element  64  and the compliant material  112 . Impulse circuitry  92  receives a pulse width modulation (PWM) signal for driving the heated sealing element  64 . A Resistance Measurement Circuitry  94  measures current draw from a known voltage. Therefore, the Resistance Measurement Circuitry  94  acts as a current sensor (e.g., feedback resistance) for determining temperature based on a linear relationship with resistance. In one exemplary embodiment, the temperature of the DC powered heat sealing element  64  is repeatedly calculated at very short time intervals. For example, the temperature of the DC powered heat sealing element may be calculated a less than 10 ms, less than 5 ms, less than or equal to 2 ms, or less than or equal to 1 ms. It is contemplated that the system  90  operates at about 281 Hz. If the system operates at about 281 Hz, the heated sealing element  64  is monitored between every about 2 ms and about 10 ms (e.g., in one embodiment about every 3.56 ms) instead of about every 20 ms if the system is operated at 50 Hz. Furthermore, although brushed motors are included on the illustration, brushless motors are also contemplated. Lines  96 ,  98  represent the encoder feedback from the respective rollers  68  driven by the motors.  FIG. 34  illustrates a cross-sectional view of the compliant material  112  and the heated sealing element (e.g., wire)  64 .  FIG. 35  illustrates the machine  50  with the encoders  81 . In this embodiment, the encoders  81  are in the drive train of the motors  100 . 
       FIGS. 36-39  schematically illustrate another exemplary embodiment of a machine  50  for converting a preformed web to the inflated cushions  12  (see  FIG. 2A ). The machine  50  may take a wide variety of different forms and the inflation, sealing and separation arrangements described below may be in the order/positions described or in any other order/position that facilitates inflation of the web  10 , sealing of the web, and separation of the web from the machine  50 . In the illustrated example, the machine  50  includes an inflation arrangement  160 , a sealing arrangement  162 , a clamping arrangement  110 , a web separation device  158 , and arms  854  around which the web  10  is fed. A spool mount  204  (e.g., spindle) receives a spool including the web material  10 . 
     The inflation arrangement  160  can take a wide variety of different forms. Any arrangement capable of providing air under increased pressure (above atmosphere) to the pouches  26  can be used. In the illustrated embodiment, the inflation arrangement  160  includes a hollow, longitudinally extending guide pin  56  and a blower  60 . A web is routed along a path indicated by arrows  200  from a supply and the pocket  23  is placed around the guide pin  56 , such that the guide pin  56  is between the inflation side edge  20  and the transverse seals  22 . The guide pin  56  aligns the web as it is pulled through the machine  50 . The guide pin  56  includes an inflation opening  102  that is fluidly connected to the blower  60  by a conduit  104 . The blower  60  inflates the web pouches  26  as the web moves past the inflation opening  102 . 
     Belts  70  are provided around respective drive rollers  68 . Each belt  70  is driven by its respective drive roller  68 . The speed of the drive rollers  68  and belts  70  are controlled by a belt speed control  67 . The belts  70  are in close proximity or engage one another, and form a curved surface  202  such that the belts  70  pull the web  10  proximate to the heat sealing element  64 . The seal  42  (see  FIG. 2 ) is formed as the web passes proximate to the heated sealing elements  64 . 
     In this embodiment, the curved surface  202  optionally eliminates the need for the compliant material used in the embodiments discussed above. For example, the curved surface  202  results in the two layers  14 ,  16  of the web  10  being more taut as the filled bags pass between the belts  70  and move toward the inside of the curve. The relatively more taut layers  14 ,  16  of the web  10  result in a better seal between the two layers  14 ,  16  of the web  10 . In another exemplary embodiment, one or both of the belts  70  are made from a compliant material or one or both of the belts are backed by a compliant material in addition to having the curved path. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element. The compliant or softer material spreads the pressure applied to the sealed area more evenly, which results in a more uniform seal. 
     With reference to  FIG. 40 , the spindle  204  for the spool of web material is illustrated on the machine  50 . A cover  206  is illustrated over the belt  70 . The cover  206  pivots around a point  210  to open for loading the belt. The web follows the path of arrows  200  and encounters an inflection point  212  when travelling through the machine  50 . 
     With reference to  FIG. 41 , the spindle  204  for the spool of web material is illustrated on the machine  50 . The cover  206  (see  FIG. 40 ) has been removed in  FIG. 41  so the belt  70  is visible.  FIG. 42  illustrates another view of the machine  50  with one of the belt assemblies removed. The belt  70  that remains is illustrated showing the curved path  202 . The motor  88  and the spindle  204  are also illustrated.  FIG. 43  illustrates another view of the machine  50  showing the spindle  204 .  FIGS. 44 and 45  illustrate another view of the machine  50 . In  FIG. 45 , the arms  854  are not illustrated so that a nozzle  214  of the inflation arrangement  160  may be seen.  FIG. 46  illustrates one of the belt assemblies including the belt  70  including the cover  206 .  FIG. 47  illustrates the belt assembly of  FIG. 46  with one of the covers removed to show the belt  70 .  FIG. 48  illustrates another view of the machine  50  showing the blower  60 , a pulley tensioner  216 , and the belt motors  88 .  FIGS. 49 and 50  illustrate different views of the belt assembly showing the curved surface  202 . 
       FIGS. 51 and 52  illustrate the spindle  204 .  FIGS. 53 and 54  illustrate the spool  220  around which the web is wrapped. A clip  222  (see  FIG. 52 ) is used for securing the spool  220  to the spindle  204 . In one embodiment, a radio-frequency identification device (RFID)  224  is included on the spool  220 . The RFID  224  may be encoded with, for example, a source of at least one of the spool  220  and the web material  10  on the spool  220 . The RFID  224  may also be encoded with the type of web material  10  (e.g., plastic) on the spool  220 . A device (e.g., the encoder  80 ) on the machine  50  reads a signal from the RFID  224  to confirm the source of the at least one of the spool  220  and the web material  10  on the spool  220 . In one embodiment, if the source of at least one of the spool  220  and the web material  10  on the spool  220  is not authorized, the device (e.g., the encoder  80 ) does not allow the machine  50  to function. In another embodiment, the device (e.g., the encoder  80 ) on the machine  50  also reads the type of web material  10  on the spool  220  for determining how the machine  50  will run. The encoder  80 , for example, may then run the machine  50  at a speed and temperature suitable for the web material  10  on the spool  220 . 
     While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, hardware, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.