Patent Publication Number: US-11376809-B2

Title: Flexible nozzle for inflation and sealing device

Description:
CROSS-REFERENCE TO RELATED APPLICANTS 
     This application is a continuation of U.S. application Ser. No. 14/678,718, filed Apr. 3, 2015, entitled “Flexible Nozzle for Inflation and Sealing Device,” which claims the benefit of U.S. Provisional Application No. 61/975,648, filed on Apr. 4, 2014, entitled “Flexible Nozzle for Inflation and Sealing Device,” the contents of which are hereby incorporated by reference in their entirety. 
    
    
     FIELD OF DISCLOSURE 
     The present disclosure relates to packaging materials. More particularly, the present disclosure is directed to devices and methods for manufacturing inflatable cushions to be used as packaging material. 
     BACKGROUND 
     A variety of inflated cushions are well known and used for sundry packaging applications. For example, inflated cushions are often used as void-fill packaging in a manner similar to or in place of foam peanuts, crumpled paper, and similar products. Also for example, inflated cushions are often used as protective packaging in place of molded or extruded packaging components. 
     Generally, inflated cushions are formed from films having two layers that are joined together by seals. The seals can be formed simultaneously with inflation, so as to capture air therein, or prior to inflation to define a film configuration having inflatable chambers. The inflatable chambers can be inflated with air or another gas or thereafter sealed to inhibit or prevent release of the air or gas. 
     Such film configurations can be stored in rolls or fan-folded boxes in which adjacent inflatable cushions are separated from each other by perforations. During use, a film configuration is inflated to form cushions and adjacent cushions or adjacent stands of cushions are separated from each other along the perforations. 
     A variety of film configurations are currently available. Many of these film configurations include seal configurations that tend to waste material, inhibit separation of adjacent inflated cushions, and/or form inflated cushions that are susceptible to under-inflation or leakage, thereby inhibiting utility. 
     Traditional inflation and sealing devices for filling and sealing the films to produce protective packaging material have a rigid nozzle inserted between the film layers to inflate the space between the layers. A device that provides greater robustness to variations in the film and its loading onto the device is desired. 
     SUMMARY 
     In accordance with various embodiments, a flexible structure inflation and sealing assembly may include a driver configured for engaging the flexible structure to drive the structure in a downstream direction longitudinally along a material path. The flexible structure inflation and sealing assembly may include a nozzle. The nozzle may include an elongated portion having a longitudinal axis aimed generally longitudinally and configured for reception in an inflation channel that extends through the flexible structure. The nozzle may include a fluid conduit including an outlet that directs a fluid from the conduit into the flexible structure. At least a portion of the nozzle may be sufficiently flexible to allow the longitudinal axis of the elongated portion to bend in a transverse, vertical, or combined direction to accommodate variable positions of the flexible structure being fed onto the nozzle. 
     In accordance with various embodiments, the nozzle may include a base having an inlet to receive an inflation fluid from a fluid source. The nozzle may include a flexible portion extending from the base and being sufficiently flexible to adapt to variation in the feed angle and direction of a flexible structure. The nozzle may include a tip region. The flexible portion may connect the base to the tip region. The flexible portion may be sufficiently flexible to allow the longitudinal axis in the tip region to move relative to the longitudinal axis defined by the base such that the longitudinal axis in the tip region and the longitudinal axis in the base can move from an aligned orientation to an unaligned orientation. The outlet may include a lateral outlet that is aimed to direct the fluid transversely with respect to the longitudinal axis. The nozzle base may include a substantially rigid tube. The base may define an inlet to receive the fluid into the conduit. The elongated portion may extend to the upstream end of the nozzle terminating at the tip region. The flexible portion may be disposed proximal to or upstream of a pinch area and the flexible structure is fed along the elongated portion to the pinch area. The nozzle base may extend upward of the pinch area. A side outlet may extend through a wall of the nozzle base. A side outlet may extend out of the flexible portion. Substantially the entire nozzle may be flexible. The flexible portion may be more flexible than the nozzle base. The flexible portion may include a spring material connecting an upstream end of the nozzle base and a downstream end of the tip region. The spring material may be a coil spring. The upstream end of the nozzle base may be closed in a longitudinal direction such that the fluid exits the nozzle before reaching the flexible portion. The tip region may be a nozzle tip, with the nozzle tip and the nozzle base being discrete structures positioned at separate ends of the flexible portion. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a top view of an uninflated material web according to an embodiment; 
         FIG. 2  is side view of the inflation and sealing assembly in accordance with various embodiments; 
         FIG. 2A  is side view of the inflation and sealing assembly in accordance with various embodiments; and 
         FIGS. 3A-C  are partial cross-sectional views of inflation nozzles in accordance with various embodiments; 
         FIGS. 3D-F  are a perspective views of the inflation nozzle being flexed in accordance with various embodiments; 
         FIG. 3G  is a side view of an inflation nozzle in accordance with various embodiments. 
         FIG. 4A  is a rear view of the inflation and sealing assembly of  FIG. 2  with a longitudinally aligned inflation nozzle; 
         FIG. 4B  is a rear view of the inflation and sealing assembly of  FIG. 2  with a flexed inflation nozzle; 
         FIG. 5A  is a top view of the inflation and sealing assembly of  FIG. 2  with a flexed inflation nozzle; 
         FIG. 5B  is a top partial view of the inflation and sealing assembly of  FIG. 2  with a flexed inflation nozzle; and 
         FIG. 6  is a partial view of the cutting assembly in accordance with various embodiments. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present disclosure is related to systems and methods for converting uninflated material into inflated cushions that may be used as cushioning or protection for packaging and shipping goods. Illustrative embodiments will now be described to provide an overall understanding of the disclosed apparatus. Those of ordinary skill in the art will understand that the disclosed apparatus can be adapted and modified to provide alternative embodiments of the apparatus for other applications, and that other additions and modifications can be made to the disclosed apparatus without departing from the scope of the present disclosure. For example, features of the illustrative embodiments can be combined, separated, interchanged, and/or rearranged to generate other embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure. 
     As shown in  FIG. 1 , a flexible structure, such as a multi-layer web  100  of film, for inflatable cushions is provided. The web includes a first film layer  105  having a first longitudinal edge  102  and a second longitudinal edge  104 , and a second film layer  107  having a first longitudinal edge  106  and a second longitudinal edge  108 . The second web layer  107  is aligned to be over lapping and can be generally coextensive with the first web layer  105 , i.e., at least respective first longitudinal edges  102 , 106  are aligned with each other and/or second longitudinal edges  104 , 108  are aligned with each other. In some embodiments, the layers can be partially overlapping with inflatable areas in the region of overlap. 
       FIG. 1  illustrates a top view of the web  100  having first and second layers  105 , 107  joined to define a first longitudinal edge  110  and a second longitudinal edge  112  of the film  100 . The first and second web layers  105 , 107  can be formed from a single sheet of web material, a flattened tube of web material with one edge has a slit or is open, or two sheets of web material. For example, the first and second web layers  105 , 107  can include a single sheet of web material that is folded to define the joined second edges  104 , 108  (e.g., “c-fold film”). Alternatively, for example, the first and second web layers  105 , 107  can include a tube of web material (e.g., a flatten tube) that is slit along the aligned first longitudinal edges  102 , 106 . Also, for example, the first and second web layers  105 , 107  can include two independent sheets of web material joined, sealed, or otherwise attached together along the aligned second edges  104 , 108 . 
     The web  100  can be formed from any of a variety of web materials known to those of ordinary skill in the art. Such web materials include, but are not limited to, ethylene vinyl acetates (EVAs), metallocenes, polyethylene resins such as low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and high density polyethylene (HDPE), and blends thereof. Other materials and constructions can be used. The disclosed web  100  can be rolled on a hollow tube, a solid core, or folded in a fan folded box, or in another desired form for storage and shipment. 
     As shown in  FIG. 1 , the web  100  can include a series of transverse seals  118  disposed along the longitudinal extent of the web  100 . Each transverse seal  118  extends from the longitudinal edge  112  towards the inflation channel  114 , and in the embodiment shown, toward the first longitudinal edge  110 . Each transverse seal  118  has a first end  122  proximate the second longitudinal edge  112  and a second end  124  spaced a transverse dimension d from the first longitudinal edge  110  of the film  110 . A chamber  120  is defined within a boundary formed by the longitudinal seal  112  and pair of adjacent transverse seals  118 . 
     Each transverse seal  118  embodied in  FIG. 1  is substantially straight and extends substantially perpendicular to the second longitudinal edge  112 . It is appreciated, however, that other arrangements of the transverse seals  118  are also possible. For example, in some embodiments, the transverse seals  118  have undulating or zigzag patterns. 
     The transverse seals  118  as well as the sealed longitudinal edges  110 ,  112  can be formed from any of a variety of techniques known to those of ordinary skill in the art. Such techniques include, but are not limited to, adhesion, friction, welding, fusion, heat sealing, laser sealing, and ultrasonic welding. 
     An inflation region, such as a closed passageway, which can be a longitudinal inflation channel  114 , can be provided. The longitudinal inflation channel  114 , as shown in  FIG. 1 , is disposed between the second end  124  of the transverse seals  118  and the first longitudinal edge  110  of the film. Preferably, the longitudinal inflation channel  114  extends longitudinally along the longitudinal side  110  and an inflation opening  116  is disposed on at least one end of the longitudinal inflation channel  114 . The longitudinal inflation channel  114  has a transverse width D. In the preferred embodiment, the transverse width D is substantially the same distance as the transverse dimension d between the longitudinal edge  101  and second ends  124 . It is appreciated, however, that in other configurations, other suitable transverse width D sizes can be used. 
     The second longitudinal edge  112  and transverse seals  118  cooperatively define boundaries of inflatable chambers  120 . As shown in  FIG. 1 , each inflatable chamber  120  is in fluid communication with the longitudinal inflation channel  114  via a mouth  125  opening towards the longitudinal inflation channel  114 , thus permitting inflation of the inflatable chambers  120  as further described herein. 
     In one preferred embodiment, the transverse seals  118  further comprise of notches  128  that extend toward the inflatable chambers  120 . As shown in  FIG. 1 , opposing notches  128  are aligned longitudinally along adjacent pairs of transverse seals  118  to define a plurality of chamber portions  130  within the inflatable chambers  120 . The notches  118  create bendable lines that allow for a more flexible web  100  that can be easily bent or folded. Such flexibility allows for the film  100  to wrap around regular and irregular shaped objects. The chamber portions  130  are in fluid communication with adjacent chamber portions  130  as well as with the inflation channel  114 . 
     A series of lines of weaknesses  126  is disposed along the longitudinal extent of the film and extends transversely across the first and second web layers of the film  100 . Each transverse line of weakness  126  extends from the second longitudinal edge  112  and towards the first longitudinal edge  110 . Each transverse line of weakness  126  in the web  100  is disposed between a pair of adjacent chambers  120 . Preferably, each line of weakness  126  is disposed between two adjacent transverse seals  118  and between two adjacent chambers  120 , as depicted in  FIG. 1 . The transverse lines of weakness  126  facilitate separation of adjacent inflatable cushions  120 . 
     The transverse lines of weakness  126  can include a variety of lines of weakness known by those of ordinary skill in the art. For example, in some embodiments, the transverse lines of weakness  126  include rows of perforations, in which a row of perforations includes alternating lands and slits spaced along the transverse extent of the row. The lands and slits can occur at regular or irregular intervals along the transverse extent of the row. Alternatively, for example, in some embodiments, the transverse lines of weakness  126  include score lines or the like formed in the web material. 
     The transverse lines of weakness  126  can be formed from a variety of techniques known to those of ordinary skill in the art. Such techniques include, but are not limited to, cutting (e.g., techniques that use a cutting or toothed element, such as a bar, blade, block, roller, wheel, or the like) and/or scoring (e.g., techniques that reduce the strength or thickness of material in the first and second web layers, such as electromagnetic (e.g., laser) scoring and mechanical scoring). 
     Preferably, the transverse width  129  of the inflatable chamber  120  is 3″ up to about 40″, more preferably about 6″ up to about 30″ wide, and most preferably about 12″. The longitudinal length  127  between weakened areas  126  can be at least about 2″ up to about 30″, more preferably at least about 5″ up to about 20″, and most preferably at least about 6″ up to about 10″. In addition, the inflated heights of each inflated chamber  120  can be at least about 1″ up to about 3″, and most preferably about 6″. It is appreciated that other suitable dimensions can be used. 
     Turning now to  FIG. 2 , an inflation and sealing assembly  132  for converting the web  100  of uninflated material into a series of inflated pillows or cushions  120  is provided. As shown in  FIG. 2 , the uninflated web  100  can be a roll of material  134  provided on a roll axle  136 . The roll axle  136  accommodates the center of the roll of web material  134 . Alternative structures can be used to support the roll, such as a tray, fixed spindle or multiple rollers. 
     The web  100  is pulled by a drive mechanism over an optional guide roller  138  that extending generally perpendicularly from a housing  141 . The guide roller  138  guides the web  100  away from the roll of material  134  and along a material path “B” along which the material is processed in a longitudinal direction “A”. In one example, the guide roller  138  may be a dancer roller which may aid in controlling the material  134 , such as keeping it from sagging between an inflation nozzle  140  and roll  134 . To prevent or inhibit bunching up of the web material  100  as it is unwound from the roll  134 , the roll axle  136  can be provided with a brake to prevent or inhibit free unwinding of the roll  134  and to assure that the roll  134  is unwound at a steady and controlled rate. However, as discussed herein, other structures may be utilized in addition to or as an alternative to use of brakes, guide rollers, or web feed mechanisms in order to guide the web  100  toward the pinch area  176  which is part of the sealing mechanism. As indicated, because the web  100  may sag, bunch up, drift along the guide roller  138 , shift out of alignment with the pinch zone  176 , alternate between tense and slack, or become subject to other variations in delivery, the inflation and sealing assembly  132  may need suitable adjustability to compensate for these variations. In accordance with various embodiments discussed herein, a nozzle  140  may be at least partially flexible. This flexibility, may allow the nozzle  140  to adapt to the direction the web  100  approaches as the web is fed towards and over the nozzle  140 , thereby making the nozzle  140  operable to compensate for or adapt too variations in the feed angle, direction, and other variations that the web  100  encounters as it is fed towards and over the nozzle  140 . 
     Preferably, the inflation and sealing assembly is configured for continuous inflation of the web  100  as it is unraveled from the roll  134 . The roll  134 , preferably, comprises a plurality of chain of chambers  120  that are arranged in series. To begin manufacturing the inflated pillows from the web material  100 , the inflation opening  116  of the web  100  is inserted around an inflation assembly, such as an inflation nozzle  140 , and is advanced along the material path “E”. In the embodiment shown in  FIG. 2 , preferably, the web  100  is advanced over the inflation nozzle  140  with the chambers  120  extending transversely with respect to the inflation nozzle  140  and side outlets  146 . The side outlets  146  may direct fluid in a transverse direction with respect to a nozzle base  144  into the chambers  120  to inflate the chambers  120  as the web  100  advanced along the material path “E” in a longitudinal direction “A”. The inflated web  100  is then sealed by the sealing assembly  103  in the sealing area  174  to form a chain of inflated pillows or cushions. 
     The side inflation area  168  is shown as the portion of the inflation and sealing assembly along the path “E” adjacent the side outlets  146  in which air from the side outlets  146  can inflate the chambers  120 . In some embodiments, the inflation area  168  is the area disposed between the inflation tip  142  and entry pinch area  176 , described below. The web  100  is inserted around the inflation nozzle  140  at the nozzle tip  142 , which is disposed at the forward most end of the inflation nozzle  140 . The inflation nozzle  140  inserts a fluid, such as pressured air, into the uninflated web material through nozzle outlets, inflating the material into inflated pillows or cushions  120 . The inflation nozzle  140  can include a nozzle inflation channel  143  there through that fluidly connects a fluid source, which enters at a fluid inlet  143   a , with one or more nozzle outlets (e.g. side outlet  146 ). It is appreciated that in other configurations, the fluid can be other suitable pressured gas, foam, or liquid. The nozzle may have an elongated portion which may include one or more of a nozzle base  144 , a flexible portion, and a tip. The elongated portion may guide the flexible structure to a pinch area  176 . At the same time the nozzle may inflate the flexible structure through one or more outlets. The one or more outlets may pass from the inflation channel  143  out of one or more of the nozzle base  144  (e.g. outlet  146 ), the flexible portion (e.g. outlet  146   b  of core  147  shown in  FIG. 3G ), or the tip  142  (e.g. outlet  148 ). 
       FIGS. 3A-C  illustrate enlarged views of a portion of various embodiments of nozzle  140 . As shown in  FIG. 3A-C , the side outlet  146  can extend longitudinally along the nozzle base  144  toward a longitudinal distance from the inflation tip  142 . In the one embodiment, the side outlet  146  originates proximate, or in some configurations, overlapping, the sealer assembly such that the side outlet  146  continues to inflate the inflatable chambers  120  about right up to the time of sealing (see, e.g.,  FIG. 2 or 2A ). This can maximize the amount of fluid inserted into the inflatable chambers  120  before sealing, and minimizes the amount of dead chambers, i.e., chambers that do not have sufficient amount of air. Although, in other embodiments, the slot outlet  146  can extend downstream past the entry pinch area  176  (see, e.g.,  FIG. 2A ), and portions of the fluid exerted out of the outlet  146  is directed into the web  100 . As used herein, the terms upstream and downstream are used relative to the direction of travel of the web  100 . The beginning point of the web is upstream and it flows downstream as it is inflated, sealed, cooled and removed from the inflation and sealing device. 
     The length of the side outlet  146  may be a slot having a length that extends a portion of the inflation nozzle  140  between the tip  142  and the entry pinch area  176 . In one example, the slot length may be less than half the distance from the tip  142  to the entry pinch area  176 . In another example, the slot length may be greater than half the distance from the tip  142  to the entry pinch area  175 . In another example, the slot length may be about half of the distance from the tip  142  to the entry pinch area  175 . The side outlet  146  can have a length that is at least about 30% of the length of the inflation nozzle  140 , for example, and in some embodiments at least about 50% of the length of the inflation nozzle  140 , or about 80% of the length  169  of the inflation nozzle  140 , although other relative sizes can be used. The side outlet  146  expels fluid out the lateral side of the nozzle base  144  in a transverse direction with respect to the inflation nozzle  140  through the mouth  125  of each of the chambers  120  to inflate the chambers  120  and chamber portions  130 . A portion of the side of the nozzle may be closed behind the tip  142 , such as about 10%, 20%, 30%, 40%, 50% or more of the nozzle. 
     The flow rate is typically about 2 to 15 cfm, with an exemplary embodiment of about 3 to 5 or cfm. The exemplary embodiment is with a blower rated at approximately 14-20 cfm. But much higher blow rates can be used, for example, when a higher flow rate fluid source is used, such as, a blower with a flow rate 1100 cfm. 
     In some configurations of the side outlet  146 , the side outlet  146  comprises a plurality of outlets, such as slots or separate holes, which extend along the nozzle base  144 . For example, the side outlet  146  can include a plurality of slots that are aligned in a series extending along the longitudinal side of the nozzle base  144  toward the inflation tip  142 , which slots can be aligned parallel to each other, or in various radial directions about the axis of the nozzle base. 
     The nozzle  140  may further include a portion with a fixed longitudinal axis X and a portion with a movable longitudinal axis Y. The nozzle  140  may further include a flexible joint which allows axis Y to be adjustable relative to axis X such that axis Y can be substantially coaxial with axis X and also be movable such that axis X and axis Y are not coaxial but may be, for example, intersecting, parallel, or skew relative to one another. 
       FIG. 3A  illustrates the nozzle  140  in accordance with various embodiments. The nozzle  140  may include nozzle base  144  which is defined by an exterior wall  145 . The exterior wall  145  defines a fluid conduit  143 . The fluid conduit  143  may have an inlet  143   a  (see also  FIGS. 3D-3F ). The exterior wall  145  may be a cylindrical tube. The exterior wall  145  may also be any other shape operable to transport a fluid there through. The side outlet  146  may extend through the exterior wall  145 . The nozzle  140  may also include tip  142 . Tip  142  may have a tapered surface  142   a . The tip may be metallic, plastic, or rubber. The tip may be a tip region able to receive and insert into an inflation channel on a flexible structure. In embodiments where the tip  142  is cylindrical, frustum or any other shape defining an axis, the axis Y may be coaxial with the axis of the cylinder defining tip  124 . 
     In various embodiments, the nozzle  140  may include axis X which may be located axially along the fluid conduit  143  longitudinally. In this orientation, the axis X may be aligned with the fluid travel through the fluid conduit  143 . The nozzle  140  may also include an axis Y, which may be located longitudinally along the longitudinal length of nozzle  140  such as, for example, at the tip  142 . The axis X and the axis Y may also or alternatively be any separate discrete portions along the longitudinal length of the nozzle  140  which may define the longitudinal direction of the nozzle  140  at those respective points. The nozzle  140  may be sufficiently flexible such that axis X and the axis Y may be aligned in one instance or out of alignment in another instant in response to a force being applied to the nozzle  140 . In one embodiment, the entire length of the nozzle may be flexible. In another embodiment, discrete sections of the nozzle  140  may be flexible. For example, the flexible area may be upstream or downstream of the inflation outlet (e.g. outlet  146 ). In various examples, one portion may be substantially rigid while another portion may be more flexible than the substantially rigid portion. The pinch area  176  may be proximate to the transition  144   b  in the nozzle between rigid and flexible, i.e. the flexible portion may start at or upstream of the pinch area  176  as shown in  FIG. 3G . For example, the nozzle may be flexible upstream of the pinch area and rigid downstream of the pinch area. In another example, the nozzle may be both flexible and rigid upstream of the pinch area. The rigid portion of the nozzle (e.g. the nozzle base  144 ) may be 1½ to 2 times the length of the flexible portion of the nozzle (e.g. core  147  and/or member  153  discussed below). 
     In accordance with various embodiments and shown in  FIG. 3A , tip  142  and nozzle base  144  may be connected by one or more flexible connectors. In one embodiment, the flexible connector may include a flexible member  153 . The flexible member  153  may extend from the nozzle base  144  to the tip  142 . The flexible member  153  may be a separate structure and/or material than either of the nozzle base  144  or the tip  142 . In one example, the flexible member  153  may be a coiled wire such as a spring which extends from the nozzle base  144  to the tip  142 . The flexible member  153  may be sufficiently flexible such that it can bend or deform in order to improve alignment between the tip  142  and the inflation opening  116  as the flexible structure  100  approaches and is fed over the nozzle. The flexible member  153  may also be sufficiently rigid such that the flexible member  153  maintains its general shape and direction, extending the tip  142  away from nozzle base  144  in the direction from which the flexible structure  100  approaches. As the flexible structure  100  approaches and the inflation opening  116  engages the tip  142 , the flexible member  153  may deflect and adapt to the orientation of the inflation opening  116  such that the inflation channel  114  slides more easily over the nozzle  140 . Similarly, if during operation the flexible structure  100  drifts out of alignment, the flexible member  153  may deflect and adapt to the orientation of the inflation channel  114 . It may be noted that as shown in the figures the inflation channel  114  is on one edge of the web  100 , however the channel may be on both edges or down the center of the web  100  on various other devices and setups. The system as disclosed herein is applicable to all types of and location of inflation channels such as those down the center of web  100  with cushions extending from both sides. 
     The flexible member  153  may attach to a nozzle base end  149  that terminates on the upstream end of the nozzle base  144 . The nozzle base end  149  may be a contiguous portion having the same material as the rest of nozzle base  144 . Alternatively, the nozzle base end  149  may be a separate material that caps the end of the nozzle base  144 . For example the nozzle base end  149  may be a flexible elastomeric material or a harder polymer or any other material known to a person of ordinary skill in the art. The nozzle base end  149  may prevent air from exiting the nozzle longitudinally. In other embodiments discussed below, nozzle base end  149  may form the entrance to a passage that extends through a flexible core  147  (see  FIG. 3C ). The nozzle base end  149  may also function as a structure to which the flexible member  153  may attach. For example, the nozzle base end  149  may be a vertical wall at the end of fluid conduit  143 . As shown in  FIG. 3A , the nozzle base end  149  may be a plug that engages within the fluid conduit  143  and also within an interior channel of the spring like flexible member  153  at the downstream end  153   a  of the flexible member, thereby connecting the two. The tip  142  may similarly be fastened to the end of the flexible member  153 . Alternatively or additionally, the downstream end  142   b  of tip  142  may be inserted into the upstream end  153   b  of interior channel  153   c  as shown for example in  FIG. 3A . In various embodiments, the nozzle base end  149  and the tip  142  may be two discrete structures separated from one another by the flexible member  153 . In one embodiment, the flexible member may be formed of a contiguous material with the nozzle base  144  and or nozzle tip  142 . The flexible member  153  may be larger in diameter or smaller in diameter than adjacent portions of the nozzle. As shown the flexible member  153  may be a similar size to the adjacent nozzle portions. 
       FIG. 3B  illustrates the nozzle  140  in accordance with another embodiment. Here as above, the nozzle  140  may include nozzle base  144  as defined by exterior wall  145 . The exterior wall  145  defines a fluid conduit  143  which may be cylindrical tube or any other shape operable to transport a fluid there through as discussed above. The side outlet  146  may be similar to the various other embodiments discussed herein. Similarly, the nozzle  140  may include the tip  142  with the axis X and axis Y being located in the same manner as discussed above. Tip  142  and nozzle base  144  may be connected by one or more flexible connectors. In accordance with this embodiment, the one or more flexible connectors may include a flexible core  147 . The flexible core  147  may have one or more of an intermediate core  147   a , first end  147   b , and a second end  147   c . In various examples, the second end of  147   c  of the flexible core  147  may be a contiguous part of tip  142 . Alternatively, the flexible core  147  may be a discrete part in which  142  attaches to the second end of  147   c  of the flexible core  147  via a fastener or the like. The flexible core  147  may be sufficiently flexible such that it can bend or deform in order to improve alignment between the tip  142  and the inflation opening  116  as the flexible structure  100  approaches and is fed over the nozzle  140 . The flexible core  147  may also be sufficiently rigid such that the flexible core  147  maintains its general shape and direction, extending to the tip  142  away from nozzle base  144  in the direction from which the flexible structure  100  approaches. In one example, the flexible core  147  may be a flexible elastomeric material. In other examples the rigidity or flexibility may be increased by utilizing various compositions or other materials. 
     As the flexible structure  100  approaches and the inflation opening  116  engages the tip  142 , the flexible core  147  may deflect and adapt to the orientation of the inflation opening  116  such that the inflation channel  114  slides more easily over the nozzle  140 . Similarly, if during operation the flexible structure  100  drifts out of alignment, the flexible core  147  may deflect and adapt to the orientation of the inflation channel  114 . 
     In one embodiment, the nozzle base  144  may be connected to tip  142  by only the flexible core  147  or, as discussed above, the nozzle base  144  may be connected to tip  142  by only the flexible member  153 . In another embodiment, the nozzle base  144  may be connected to tip  142  by more than one flexible element. For example, the flexible member  153  may be added to the exterior of flexible core  147 . The flexible core  147  may be positioned coaxially to the flexible member  153 . While both the flexible core  147  and the flexible member  153  may be flexible, they may have differing functions. For example, the flexible member  153  may have a metal surface or a surface of another suitable material that facilitates transition of the inflation channel  114  by reducing friction. Whereas the flexible core  147  may provide longitudinal support to the flexible member  153 . Alternatively or additionally, as illustrated in  FIG. 3C , the flexible core may provide a channel through one or more of the flexible elements allowing the nozzle  140  to include a longitudinal outlet, such as a nozzle tip outlet  148 . Specifically, the inflation tip  142  may include a nozzle tip outlet  148  that is fluidly connected to the fluid conduit  143  within the nozzle base  144  to expel fluid upstream out of the nozzle tip outlet  148 . The nozzle base  144  may have a longitudinal axis extending along and defining the material path “E,” and the tip outlet  148  may be aimed from the nozzle base  144  and flexible element in the direction that the flexible structure  100  approaches the nozzle  140 , which may be generally an upstream direction B along the longitudinal axis. In this embodiment, the nozzle base  144  defines the material path “E” laterally adjacent thereto. 
     In inflation nozzles not including a tip outlet  148 , the tip of the inflation nozzle can be used to pry open and separate the web layers in an inflation channel at the tip as the material is forced over the tip. For example, when the web is pulled over traditional inflation nozzles, the tip of the traditional inflation nozzles forces the web layers to separate from each other. In some embodiments, the majority of the fluid from the fluid source is expelled from the side outlet  146 , but a portion of the fluid may be expelled from the nozzle tip outlet  148  to improve the material flow of the web  100  over the nozzle. The portion of the fluid being expelled from the nozzle tip outlet  148  creates a pressurized flow, producing a pressurized column of the fluid upstream of the nozzle  140  that can act as a guide that pre-aligns the web  100  with the nozzle  140  and separates the layers upstream of and before they reach the nozzle tip  142 . As the layers arrive at the tip separated, they do not need to be pried or wedged apart by the tip  142 , which reduces noise and vibration caused in traditional inflation nozzles. 
     This longitudinal outlet may be in addition to or in the absence of a lateral outlet, such as side outlet  146 , which may be downstream of the tip outlet  148  and along the longitudinal side of the nozzle wall of the nozzle base  144  of the inflation nozzle  140 . The nozzle tip outlet  148  may be at the upstream-most tip  142  of the nozzle  140  with respect to the material flow direction along the path A, at the distal end of the inflation nozzle  140 . The side outlet  148  may be the principal outlet that provides the primary fluid source for inflating the chambers  120 , and the nozzle tip outlet  148  operates to stabilize the advancing web  100  as it approaches the inflation nozzle  140 . It is appreciated that the fluid expelled from the nozzle tip outlet  148  can also help inflate the chambers  120 . 
       FIG. 3C  depicts a side view of the nozzle  140  expelling fluid  151  from the nozzle tip outlet  148  into the inflation channel  116  of the web  100 . As illustrated in  FIG. 3C , the fluid  151  being expelled from the nozzle tip outlet  148  forms the expanded, fluid-pressurized column  150  that separates the first web layer  105  and second web layer  107  and also acts as a guide to guide the web  100  over the inflation nozzle  140 . This facilitates the inflation channel  114  of the web  100  to easily slide over the inflation nozzle  140 , which allows for faster inflation of the web  100  because the web  100  can be pulled over inflation nozzle  140  quicker with less resistance. Further, expelling fluid out of the tip outlet  148  increases the life of the nozzle tip  142 . While the tip outlet  148  is sufficiently aligned with the nozzle axis to achieve the above effects. The diameter  148   a  of the tip outlet  142  and amount of fluid expelled from the tip outlet  142  may be sufficient to expel a pressurized flow sufficient to push and separate the first and second web layers  105 , 107  from each other to facilitate sliding the web over the inflation nozzle  140 . 
     The tapered end of the inflation tip  142  facilitates the easy sliding of the inflation channel  114  over the inflation nozzle  140  in addition to the fluid  150  being expelled from the tip outlet  148 . The inflation tip  142  may have the nozzle tip outlet  148  in some embodiments and may not have the nozzle tip outlet  148  in other embodiments. In one example, the tip  142  may be a contiguous portion of the flexible core  147  as shown in  FIG. 3B  without the nozzle tip outlet  148 . In one example, the tip  142  may be a contiguous portion of the flexible core  147  as shown in  FIG. 3C  with the nozzle tip outlet  148 . In one example, the tip  142  may be a discrete portion of the nozzle  140  not attached to a flexible core as shown in  FIG. 3A  and used without the nozzle tip outlet  148 . While  FIG. 3A  shows the nozzle base end  149  as being relatively short compared to the length of the flexible member  153 , the nozzle base end  149  may be any length. For example the nozzle base end  149  may be long enough to contact the discrete tip  142  and provide support to the flexible member  153  similar to the example shown in  FIG. 3B . 
       FIG. 3D  illustrates one embodiment of the inflation nozzle. The inflation tip  142  can have a conical shape with a tapered end extending upstream the assembly. The tip  142  and upstream end portion of the nozzle may be displaced out of alignment with the inflation nozzle base  144 . As shown in  FIG. 3D , this deflection may be measured transversely (relative to the feed direction) as depicted by distance H. This may be in the same direction or plane as the outlet  146 . Additionally or alternatively, as shown in  FIG. 3E , the deflection may be measured vertically as depicted by distance V. This vertical direction may be measured perpendicular to the feed direction and/or perpendicular to the transvers direction of the material. As shown in  FIG. 3F , this deflection may be a combination of lateral deflection and vertical deflection giving the tip a full range of motion as depicted by the various tips and arrows shown in  FIG. 3F . In one example, the end of the nozzle may deflect such that it forms an angle A of less than about 90° and more than 0° along the longitudinal axis (e.g. axis X and Y discussed above form an acute angle) as viewed from the upstream end of the nozzle  140  (see  FIGS. 3D and 3E ). In one example, the end of the nozzle may deflect such that it forms an angle A of less than about 60° and more than 0° along the longitudinal axis (e.g. axis X and Y discussed above form a about 55° angle) as viewed from the upstream end of the nozzle  140  (see  FIGS. 3D and 3E ). In one example, the end of the nozzle  140  may deflect such that it forms an angle A between about 5° and about 45° along the longitudinal axis (i.e. axis X and Y discussed above form an angle between about 5°-45°) as viewed from the upstream end of the nozzle  140  (see  FIGS. 3D and 3E ). In various embodiments, the flexibility of the nozzle  140  may be such that a force of 1 pound on the tip  142  is sufficient to fully deflect the nozzle. The Nozzle  140  may be sufficiently flexible to bend in response to misaligned inflation channel on the flexible structure but be sufficiently ridged to direct the inflation channel of the flexible structure toward the pinch area  176 . 
     In various embodiments, the inflation nozzle  140  is positioned horizontally with respected to the horizontal plane  152  as shown in  FIGS. 2 and 4A -B. In other embodiments the inflation nozzle  140  may be angled such that it aligns material path “E” of the sealing assembly to approach the nozzle  140  in a downward, slanted angle. The angle can also be such that the path approaches in an upward direction. In various examples, the angle of the nozzle  140  relative to the horizontal plane  152  may be about 5° or 10° upwards from the horizontal in an upstream direction, or to up to about 30°, 45°, or 60° with respect to the horizontal plane  152 . The inflation nozzle base  144  and its longitudinal axis X may be aligned tangentially to the sealing drum. As indicated elsewhere, the nozzle  140  may be flexible. So while it may have a general longitudinal orientation and angle relative to the base plane, that general orientation may be movable due to flexibility of the nozzle. 
       FIGS. 4A and 4B  show rear views of the inflation and sealing assembly. As shown in  FIG. 4A  the axes X, Y of the nozzle base  144  and the nozzle tip  142 , respectively, are aligned. As is typical in traditional inflation and sealing devices, the web  100  may have to be aligned with a rigid nozzle. This alignment may take physical manipulation of the web or even if the opening  116  of the longitudinal channel  114  where aligned from the start, continued operation of the inflation and sealing assembly device may result in a tendency for the longitudinal channel  114  to drift out of alignment. This may substantially increase the forces against the nozzle  140  to maintain alignment. Increased forces may result in drag on the web  100  and potential failure of the inflation and sealing assembly device. As shown in  FIG. 4B  the axes X, of the nozzle base  144  and the nozzle tip  142 , respectively, are not in alignment. When out of alignment from this view, the flexible connector is also shown. By providing a flexible portion between tip  142  and base  144 , their relative axes are able to misalign. This misalignment may ease the insertion of the nozzle  140  into the opening  116  of the web  100  and or the misalignment may reduce forces between the web  100  and the nozzle  140  in response to the web  100  drifting out of alignment, thereby improving operation of the inflation and sealing assembly device.  FIGS. 5A and 5B  further illustrate the operability of the nozzle  140  to misalign with the web  100 . As shown, a roll  134  or web  100  is mounted on the inflation and sealing assembly  132 . Nozzle  140  is engaged within the inflation channel  114 . Notably shown in the  FIGS. 5A and 5B  is that the inflation channel  114  is not linear. Instead, the inflation channel has engaged tip  142 , bent around the flexible member  153 , and then continued over the nozzle base  144 . The axis X of the nozzle base  144  and the axis Y of the tip  142  are not aligned but are instead misaligned providing for a gradual transition of the inflation channel  114  around the nozzle from a misaligned state to an aligned state on the nozzle base  144 . 
       FIG. 2A  illustrates a side view of the preferred inflation and sealing assembly  101 . As shown, the fluid source can be disposed behind a housing plate  184  or other structural support for the nozzle and sealing assemblies, and preferably behind the inflation nozzle  140 . The fluid source is connected to and feeds the fluid inflation nozzle conduit  143 . The web  100  is fed over the inflation nozzle  140 , which directs the web to the inflation and sealing assembly  101 . The web  100  is advanced or driven through the inflation and sealing assembly by a drive mechanism, such as by a driver or sealing drum  166   a  or the drive roller  160 , in a downstream direction along a material path “E”. In accordance with various embodiments, any of the rollers or drums may drive the system. 
     When viewed from the top, in  FIG. 2A , facing one of the principal surfaces of the upper film layer, in a transverse direction extending between the drum  17  and the belt  162 , the sealing assembly  103  is positioned transversely between the nozzle and the chambers being inflated to seal across each of the transverse seals. Some embodiment can have a central inflation channel, in which case a second sealing assembly and inflation outlet may be provided on the opposite side of the nozzle. Other known placement of the web and lateral positioning of the inflation nozzle and sealing assembly can be used. 
     Preferably, the sealing assembly is attached to the housing plate  184 . The sealing assembly  103  includes one or more traction members, such as belts  162   a  and  162   b , which are wrapped along rotating members, such as rollers. Belt  162   a,b  may be wrapped around tension rollers  156   a,b , roller  158   a,b , and rollers  160   a,b , (any of which may be the drive roller) although in other embodiments, a plurality of belts or a single belt can be used. After inflation, the web  100  is advanced along the material path “E” towards a web feed area  164  where it enters the sealing assembly  103 . The web feed area  164  may disposed between the belts  162   a,b  although in other embodiments of machines with a single belt the area may be between a pinch roller and drum  166   a . The web feed area  164  can include an entry pinch area  176 . The entry pinch area  176  is the region in which the first and second web layers  105 , 107  are pressed together or pinched to prevent fluid from escaping the chambers  120  and to facilitate sealing by the sealing assembly  103 . The pinch area  176  may be the area where belts  162   a,b  are in contact or the pinch area may be between the sealing drum and the portion of the belt downstream of the pinch roller. The belts  162   a,b  or other pinch area components may have sufficient tension to tightly pinch or press the web layers  105 , 107  together against the drum  17 . 
     The belts  162   a,b  may be driven in a drive path or direction shown by arrow “C” in  FIG. 2A  by the rollers. The drive rollers  160   a,b  may associated or connected with a drive mechanism that rotates the drive rollers  160   a,b  to move the belt  162  along the drive path “C” and advance the web  100 . Preferably, the drive mechanism is connected to a motor located within the housing  141 . The drive mechanism can include gears or the like located behind the housing  141  to transfer the power from the motor to the drive rollers. Preferably, the tension rollers  156   a,b  are free spinning, and rotate in response to belt  162  being moved by the rotation of the drive roller  160 . It is appreciated, however, that in other configurations, the tension roller  156   a,b  can be associated or connected with the drive mechanism to independently rotate or to act as the drive rollers to drive the belts  162   a,b  along the drive path “C”. In other embodiments, multiple cooperating belts can be used against the opposed layers, or rollers can directly guide and operate on the layers past rotating or stationary heaters or other sealing members. 
     After being fed through the web feed area  164 , the first and second web layers  105 , 107  are sealed together by a sealing assembly  103  and exit the sealing drum  166   a . In various embodiments, the sealing assembly  103  includes a sealing drum  166   a . The sealing drum  166   a  includes heating elements, such as thermocouples, which melt, fuse, join, bind, or unite together the two web layers  105 , 107 , or other types of welding or sealing elements. 
     After the sealing drum  166   a  the first and second web layers  105 , 107  are cooled allowing the seal to harden by rolling the sealed the first and second web layers  105 , 107  around a cooling roller  166   b . The cooling roller  166   b  may act a heat sink or may provide a sufficient cooling time for the heat to dissipate into the air. 
     Preferably, the web  100  is continuously advanced through the sealing assembly  103  along the material path “E” and past the sealing drum  166   a  at a sealing area  174  to form a continuous longitudinal seal  170  along the web by sealing the first and second web layers  105 , 107  together, and exits the sealing area  174  at an exit pinch area  178 . The exit pinch area  178  is the area disposed downstream the entry pinch area  164  between the belt  162  and the sealing drum  166   a , as shown in  FIG. 7 . The sealing area  174  is the area between the entry pinch area  164  and exit pinch area  178  in which the web  100  is being sealed by the sealing drum  166   a . The longitudinal seal  170  is shown as the phantom line in  FIG. 1 . Preferably, the longitudinal seal  170  is disposed a transverse distance from the first longitudinal edge  102 , 106 , and most preferably the longitudinal seal  170  is disposed along the mouths  125  of each of the chambers  120 . 
     In the preferred embodiment, the sealing drum  166   a  and one or more of belts  162   a,b  cooperatively press or pinch the first and second web layers  105 , 107  at the sealing area  174  against the sealing drum  166   a  to seal the two layers together. The sealing assembly  103  may rely on the tension of the belts  162   a,b  against the sealing drum  166   a  to sufficiently press or pinch the web layers  105 , 107  there between. Although, an abutting roller may be used as well. The flexible resilient material of the belts  162   a,b  allows for the tension of the belts to be well-controlled by the positions of the rollers. 
     In the embodiment shown, the web  100  enters the sealing assembly at the entry pinch area  176  horizontally. Although in other embodiments the web  100  may enter the sealing assembly at entry to the pinch area that is at a downward angle relative to the horizontal. Additionally, the web  100  exits the sealing assembly  104  at an angle sloped upward with the respect to the horizontal so that the web  100  is exiting facing upwards toward the user. Although, horizontal and downward departures are also contemplated herein. 
     In accordance with various embodiments, the inflation and sealing device  101  may further include a cutting assembly  186  to cut the web. The cutting assembly  186  may cut the first and second web layers  105 , 107  between the first longitudinal edge  102  and mouth  125  of the chambers. In some configurations, the cutting assembly  186  may cut the web  100  to open the inflation channel  114  of the web  100  and remove the first and second layers  105 , 107  from the inflation nozzle  140 . 
     As illustrated in  FIG. 6 , the cutting assembly  186  can include a cutting device or cutting member, such as a blade  192  with a cutting edge  188 , and a cutter holder, such as cutter holder  190 , mount, or housing member. Preferably, the cutting member is mounted on a holder  190 . Preferably, the cutting member is sufficient to cut the web  100  as it is moved past the edge along the material path “E”. In the various embodiments, the cutting member is a blade  192  or knife having a sharp cutting edge  188  and a tip  210  at the distal end  196  of the blade  192 . In the embodiment shown, the cutting edge  188  is preferably angled upward toward the inflation nozzle  140 , although other configurations of the cutting edge  188  can be used. 
     As shown in  FIG. 6 , the cutter holder  190  holds the blade  192 . This may be done magnetically, with a fastener, or any other method known. The blade  192  may be received within a recessed area  191  of the cutter holder  190 . The recessed area  191  preferably having walls to position and align the blade  192  in a fixed position within the cutter holder  190 . In various embodiments, the cutting assembly  186  may be a fixed assembly or a movable one such as those described in U.S. application Ser. No. 13/844,658. The blade  192  may engage slot  211  on the nozzle base  144 . This engagement may position the blade  192  relative to the nozzle base  144  such that, as the web  100  slides over the nozzle base  144 , the web engages the blade  192  and is cut thereby. 
     The door  218  can further include a door handle  236  to facilitate easy opening of the door  218  when the cutting holder  190  is removed from the inflation and sealing assembly  103  so that a user, for example, can remove the blade  192  from the cutter holder  190 . While the embodiment shown shows a door  218 , it is appreciated that other embodiments may not include the door  218 . 
     In other embodiments, it&#39;s appreciated that a cutter housing  190  can be omitted, and other suitable mechanisms can be used to position the blade  192  adjacent the inflation nozzle  140 . Although the cutting assembly  186  is shown, in other embodiments, traditional cutter arrangements can be used, such as a fixed cutter, rotary cutter, or other cutters known in the art. 
     It is appreciated, that the inflation nozzle  140  described herein can also be used on other types of film handling devices in and inflating and sealing devices. An example is disclosed U.S. Pat. Nos. 8,061,110 and 8,128,770, U.S. Publication No. 2011/0172072, and U.S. application Ser. No. 13/844,658. 
     Any and all references specifically identified in the specification 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. 
     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.