Patent Publication Number: US-2015069106-A1

Title: Web for making fluid filled units

Description:
RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/876,140, filed Sep. 10, 2013, and U.S. Provisional Patent Application Ser. No. 61/976,546, filed Apr. 8, 2014, both titled DOUBLE BUBBLE WEB. Provisional application Nos. 61/876,140 and 61/876,546 are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     The present invention relates to fluid filled units. It finds particular application in conjunction with plastic webs of interconnected pouches and to processes of converting interconnected pouches to fluid filled 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 sealed air filled pouches from sheets of plastic are known. Machines which produce sealed air filled pouches by inflating preformed pouches in a preformed web are also known. For many applications, machines which utilize preformed webs are preferred. 
     Typically, the entire length of sides of adjacent sealed air filled pouches formed from a preformed web are connected by perforations. In prior art webs, these perforations extend all the way to an inflation edge of the web. 
     SUMMARY 
     In one aspect of the present invention, a web for forming sealed air filled pouches includes a first elongated layer and a second elongated layer superposed over the first elongated layer. The first and second layers are connected together at an inflation edge and an opposite edge. A plurality of transverse seals extend from the opposite edge to a seal termination point that is a distance from the inflation edge. The inflation edge, the opposite edge, and the transverse seals form a plurality of inflatable pouches. A plurality of fold seals seal the first and second elongated layers together along a fold area defining first and second chambers. The fold seals create a cushioned area along the fold area when the first chamber is folded over the second chamber. 
     In another aspect of the present invention, a device for separating pouches defined by lines of perforations in a web includes a first stage including a first belt operating at a first speed and a second stage including a second belt operating at a second speed. The web passes through the first stage before passing through the second stage. A pouch is separated from the web at the lines of perforations when a relative speed of the first belt is slower than a speed of the second belt by a predetermined threshold. 
    
    
     
       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  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 2  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 2A  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 3  illustrates a schematic representation of a web with pouches inflated and sealed to form fluid filled units; 
         FIG. 4  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 5  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 6  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 7A  illustrates a schematic representation of a plan view of a process and machine for converting web pouches to fluid filled units; 
         FIG. 7B  illustrates a schematic representation of a plan view of a process and machine for converting web pouches to fluid filled units; 
         FIG. 8A  illustrates a schematic representation of an elevational view of the process and machine for converting web pouches to fluid filled units; 
         FIG. 8B  illustrates a schematic representation of an elevational view of the process and machine for converting web pouches to fluid filled units; 
         FIG. 9  illustrates a schematic representation of a process for converting web pouches to fluid filled units; 
         FIG. 10  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 10A  illustrates a schematic representation of a web for making fluid filled units; 
         FIG. 11  illustrates a schematic representation of a web of pouches inflated and sealed to form fluid filled units; 
         FIG. 12  illustrates a schematic representation of a plan view of a cutter for opening the inflation edge of a web; 
         FIG. 13  illustrates an exemplary embodiment of a web for making fluid filled units; 
         FIG. 13A  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 13B  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 13C  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 13D  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 13E  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 13F  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 13G  illustrates an exemplary embodiment of a of a web for making fluid filled units; 
         FIG. 14  illustrates a representation of a staggered pattern of internal seals; 
         FIGS. 15-17  illustrate representations of inflated pouches folded in various stages; 
         FIG. 18  illustrates a schematic representation of a device for separating the web into individual pouches or sets of the pouches; 
         FIGS. 19 ,  20 , and  21  illustrate different schematic views of a device for separating the web into individual pouches or sets of the pouches; 
         FIG. 22  is a flow chart diagram of a process followed by one particular embodiment of the device illustrated in  FIGS. 19 ,  20 , and  21 ; 
         FIGS. 23-26  illustrate the steps of the process shown in the flow chart diagram in  FIG. 22 ; 
         FIG. 27  is a flow chart diagram of a process followed by one particular embodiment of the device illustrated in  FIGS. 19 ,  20 , and  21 ; and 
         FIGS. 28-31  illustrate the steps of the process shown in the flow chart diagram in  FIG. 27 . 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT 
     Referring to  FIGS. 1 and 2 , exemplary illustrations of webs  10  of inflatable pouches  12  are shown. The webs  10  include a top elongated layer of plastic  14  superposed onto a bottom layer of plastic  16 . The layers  14 ,  16  are connected together along spaced edges, referred to as the inflation edge  18  and the opposite edge  20 . In the example illustrated by  FIG. 1 , each of the edges  18 ,  20  is either a fold or a seal that connects the superposed layers  14 ,  16  along the edges  18 ,  20 . The connection at the opposite edge  20  is illustrated as a hermetic seal and the connection at the inflation edge  18  is illustrated as a fold in  FIG. 1 . However, the fold and the seal could be reversed or both of the connections could be seals in the  FIG. 1  embodiment. 
     In the example illustrated by  FIG. 2 , the inflation edge  18  comprises a frangible connection  21  and the opposite edge  20  is a hermetic seal. The illustrated frangible connection  21  is a line of perforations. The size of the perforations is exaggerated to clarify  FIG. 2 . The frangible connection  21  may be formed by folding the inflation edge  18  and pulling the inflation edge over a serration forming wheel (not shown).  FIG. 2A  illustrates a web  10  of inflatable pouches  12  in which a frangible connection  21 ′ is present in one of the superposed layers, in the described embodiment layer  14 , at a location offset from the inflation edge  18  by a distance D4. In an exemplary embodiment, the distance D4 is between about 0.075 inches and about 0.2 inches, in an exemplary embodiment between about 0.09375 inches and about 0.15625 inches. The frangible connection can be formed in a wide variety of different ways any of which can be used. For example, the frangible connection  21 ′ can be formed by pulling the web over a serration forming wheel (not shown) prior to folding the inflation edge or by providing a serration backing plate (not shown) interposed between the layers where the serration forming wheel contacts the web so that only a single layer is acted on by the wheel. 
     Referring to  FIGS. 1 ,  2 ,  2 A a plurality of longitudinally spaced, transverse seals  22  join the top and bottom layers  14 ,  16 . Generally, each transverse seal  22  extends from the opposite edge  20  to within a short distance of the inflation edge  18 . Spaced pairs of lines of perforations  24 ,  26  extend through the top and bottom layers terminating a short distance from the edges  18 ,  20  respectively. A gap forming area  28  extends between each associated pair of lines of perforations  24 ,  26 . The gap forming area  28  opens to form a gap  13  when the pouches are inflated (see  FIG. 3 ). 
     A gap forming area  28  denotes an area, preferably linear in shape, that will rupture or otherwise separate when exposed to a predetermined inflation force. The magnitude of the inflation force is less than the magnitude of the force needed to rupture or separate the spaced apart lines of perforations  24 ,  26 . The gap forming area  28  can take on a number of embodiments, as will be discussed below. Any method that produces an area between the spaced apart lines of perforations  24 ,  26  that ruptures or otherwise separates at a force lower than a force needed to rupture or separate spaced lines of perforations  24 ,  26  may be employed to make the gap forming area  28 . 
     Referring to  FIG. 3 , the web  10  of pouches  12  ( FIGS. 1 ,  2 ,  2 A) is inflated and sealed to form a row  11  of sealed air filled pouches  12 ′. The formed sealed air filled pouches  12 ′ are configured to be much easier to separate from one another than prior art arrays of sealed air filled pouches. In the exemplary embodiment of  FIG. 3 , each adjacent pair of sealed air filled pouches  12 ′ is connected together by a pair of spaced apart lines of perforations  24 ,  26 . The spaced apart lines of perforations  24 ,  26  are spaced apart by a gap  13 . A single row  11  of sealed air filled pouches  12 ′ can be graphically described as being in a “ladder” configuration. This configuration makes separating two adjacent sealed air filled pouches  12 ′ much easier than separating prior art arrays of dunnage units. To separate a pair of adjacent sealed air filled pouches  12 , a worker simply inserts an object or objects, such as a hand or hands, into the gap  13  and pulls one dunnage unit  12 ′ away from the other dunnage unit  12 ′. In the alternative, a mechanical system can be used to separate sealed air filled pouches  12 ′. A machine can be configured to insert an object between adjacent sealed air filled pouches  12 ′ and apply a force to separate the units 
     Referring to  FIGS. 1-3 , prior to conversion to a dunnage unit, a pouch is typically hermetically sealed on three sides, leaving one side open to allow for inflation. Once the pouch is inflated, the inflation opening is hermetically sealed and the dunnage unit is formed. During the inflation process, as the volume of the pouch increases the sides of the pouch have a tendency to draw inward. Drawing the sides of the pouches inward will shorten the length of the sides of the pouch unless the sides of the pouch are constrained. In this application, the term foreshortening refers to the tendency of the length of a pouch side to shorten as the pouch is inflated. In prior art webs, the sides of the pouch are restrained, because sides of adjacent pouches are connected by lines of perforations that extend along the entire length of the pouches and remain intact during and after inflation. The foreshortening of the unrestrained sides, such as the inflation opening, may not be uniform. Restraining the sides of adjacent connected pouches can cause undesirable inflation induced stresses. These undesirable stresses may be caused because sides of adjacent pouches are connected and restrained, thus, limiting inflation and causing wrinkles to develop in the layers at the unrestrained inflation opening. The wrinkles can extend into a section of the inflation opening to be sealed to complete the dunnage unit, which may comprise the seal. One reason the seal can be compromised is that wrinkling can cause sections of the layers  14 ,  16  to fold on top of one another. A sealing station of a dunnage machine is typically set to apply the appropriate amount of heat to seal two layers of material. The sealing of multiple layers of material in the area of a wrinkle results in a seal that is weaker than remaining seal areas and may result in a small leak or tendency to rupture at loads lower than loads at which the sealed air filled pouches is designed to rupture. 
     In the embodiment illustrated by  FIG. 3 , the gap forming area  28 , produces a gap  13  between adjacent pouches upon inflation. The gap allows foreshortening of the connected pouch sides and thereby reduces the undesirable stresses that are introduced during inflation as compared with prior art webs. In addition, the web with a gap  13  facilitates fuller inflation of each pouch. The gap  13  maintains the inflation opening substantially free of wrinkles as the inflation opening is sealed to convert the inflated pouches to sealed air filled pouches. 
     The illustrated web  10  is constructed from a heat sealable plastic film, such as polyethylene. The web  10  is designed to accommodate a process for inflating each pouch  12  in the web to create a row or ladder  11  of sealed air filled pouches  12 ′. The gap forming area  28  creates a gap  13  between sealed air filled pouches  12 ′, which facilitate a efficient and effective process for separating adjacent sealed air filled pouches  12 ′ in the row or ladder  11 . 
     In the example illustrated by  FIG. 4 , the gap forming area  28  defined by the web  10 ′ includes an easily breakable line of perforations  29  between the spaced lines of perforations  24 ,  26 . The force needed to rupture or separate the line of perforations  29  is less than the force needed to separate the perforations  24 ,  26  extending inward of the web edges  18 ,  20 . Each pair of perforations  24 ,  26  and associated more easily breakable line of perforations  29  divide the transverse seal  22  into two transverse sections. As a pouch  12  is inflated, the line of perforation  29  begins to rupture or separate leading to the development of a gap  13  between the produced sealed air filled pouches  12 ′ (See  FIG. 3 ). Once the pouch  12  is fully inflated, the line of perforations  29  is fully or nearly fully ruptured; however the perforations  24 ,  26  at the edges remain intact. These perforations  24 ,  26  are ruptured or separated when a worker or automated process mechanically separates the perforations  24 ,  26 . 
       FIG. 5  illustrates another embodiment of the web  10 ″. In this embodiment the gap forming area  28  comprises an elongated cut  31  through both layers of material  14 ,  16 . The cut  31  extends between each associated pair of lines of perforations  24 ,  26 . In the embodiment illustrated by  FIG. 5 , pairs  30  of transverse seals  22 ′ extend from the opposite edge  20  to within a short distance of the inflation edge  18 . Each of the pairs of lines of perforations  24 ,  26  and corresponding cuts  31  are between an associated pair of transverse seals  30 . It should be readily apparent that the seal  22  shown in  FIG. 4  could be used with the cut  31  shown in  FIG. 5 . It should also be readily apparent that the line of perforations shown in  FIG. 4  could be used with the transverse seals  22 ′ shown in  FIG. 5 . It should be additionally apparent that any gap forming area  28  can be used with either of the transverse seal configurations  22 ,  22 ′ shown in  FIGS. 4 and 5 . 
       FIG. 6  illustrates a further embodiment of the web  10 ′″. In this embodiment, the gap forming area  28  comprises at least two elongated cuts  32 , separated by light connections of plastic  36 , also referred to as “ticks.” These connections  36  hold transverse edges  38 ,  40  of the pouches  12  together to ease handling of the web  10 , such as handling required during installation of the web  10  into a dunnage machine. As the pouches  12  are inflated, the connections  36  rupture or otherwise break resulting in a gap  13  between the spaced pairs of perforations  24 ,  26 . This gap  13  allows for full inflation and reduces the stresses in the layers at the seal site normally caused by the foreshortening and restrictions on foreshortening of webs in the prior art. The reduced stress in the layers inhibits wrinkles along the inflation opening to be sealed. 
     Other methods of creating a gap forming area not specifically disclosed are with the scope of the present application. Any area that separates and forms a gap between adjacent pouches as pouches  12  in a web  10  are inflated are contemplated by this disclosure. 
       FIG. 3 , illustrates a length of the web  10 ,  10 ′,  10 ″ or  10 ′″ after it has been inflated and sealed to form sealed air filled pouches  12 ′. An inflation seal  42 , the transverse seals  22  and an opposite edge seal  44  hermetically seal the top and bottom layers. The side edges  38 ,  40  of the formed sealed air filled pouches are separated to form a gap  13 . Each pair of adjacent sealed air filled pouches  12 ′ are connected together by the pair of spaced apart lines of perforations  24 ,  26 . The gap  13  extends between the pair of spaced apart lines of perforations  24 ,  26 . The array of sealed air filled pouches  12 ′ is a single row of sealed air filled pouches in a “ladder” configuration. The lines of perforations  24 ,  26  are configured to be easily breakable by a worker or automated system. To separate a pair of adjacent units  12 ′, a worker inserts an object, such as the worker&#39;s hand or hands into the gap  13 . The worker then grasps one or both of the adjacent sealed air filled pouches  12 ′ and pulls the adjacent sealed air filled pouches  12 ′ relatively apart as indicated by arrows  43   a ,  43   b . The lines of perforation  24 ,  26  rupture or otherwise separate and the two adjacent sealed air filled pouches  12 ′ are separated. The existence of the gap  13  also results in reduced stresses in the area of the inflation seal  42  at the time of sealing and accommodates increased inflation volume of the sealed air filled pouches  12 ′ as compared with prior inflated sealed air filled pouches. 
     In one embodiment, the line of perforations  24  that extends from the opposite edge  20  is omitted. In this embodiment, the gap forming area  28  extends from the inflation edge line of perforations  26  to the opposite edge. In this embodiment, the gap  13  extends from the inflation edge line of perforations  26  to the opposite edge  20 . 
     The connection of the layers  14 ,  16  at the inflation edge  18  can be any connection that is maintained between layers  14 ,  16  prior to the web  10  being processed to create sealed air filled pouches  12 ′. In the embodiment illustrated by  FIGS. 1 and 2A , the connection is a fold. In the embodiment illustrated by  FIG. 2 , the connection is a line of perforations  21 . One method of producing such a web is to fold a continuous layer of plastic onto itself and create a fold at what is to become the inflation edge  18 . A tool can be placed in contact with the fold to create a line of perforation. The opposite edge  20  can be hermetically sealed and the transverse hermetic seals  22  can be added along with the separated lines of perforations  24 ,  26  extending inward from the inflation and opposite edges  18 ,  20 . The web shown in  FIG. 1  can be produced in the same manner, except the perforations are not added. 
       FIGS. 7A ,  7 B,  8 A,  8 B and  9  schematically illustrate a machine  50  and process of converting the webs  10 ,  10 ′,  10 ″ and 10′″ to sealed air filled pouches  12 ′. Referring to  FIGS. 7A ,  7 B,  8 A and  8 B, a web  10 ,  10 ′,  10 ″ or  10 ′″ is routed from a supply  52  ( FIGS. 8A and 8B ) to and around a pair of elongated, transversely extending guide rollers  54 . The guide rollers  54  keep the web taught as the web  10  is pulled through the machine  50 . At location A, the web pouches are uninflated. In the embodiment illustrated by  FIG. 5 , pouch edges  38 ,  40  defined by the cut  31  are close to one another at location A. In the embodiments illustrated by  FIGS. 4 and 6 , the frangible connections  29 ,  36  are of sufficient strength to remain intact at location A. 
     A longitudinally extending guide pin  56  is disposed in the web at station B. The guide pin  56  is disposed in a pocket bounded by the top and bottom layers  14 ,  16 , the inflation edge  18 , and ends of the transverse seals  22 . The guide pin  56  aligns the web as it is pulled through the machine. A separator, such as a knife cutter  58  ( FIGS. 7A and 8A ), or a blunt surface  58 ′ ( FIGS. 7B and 8B ) is present on the guide pin  56 . In the embodiment illustrated by  FIGS. 7A and 8A  the knife cutter  58  extends from the guide pin  56 . The knife cutter  58  is used to cut the inflation edge  18  illustrated by  FIG. 1 , but could also be used to cut the perforated inflation edge  18  illustrated by  FIG. 2 . The cutter  58  slits the inflation edge  18  as the web moves through the machine  50  to provide inflation openings  59  (See  FIG. 9 ) into the pouches, while leaving the pouches otherwise imperforate. A variation of this would have the cutter  58  cutting either layer  14 ,  16 , or both near the inflation edge  18 . In the embodiment illustrated by  FIGS. 7B and 8B , the guide pin  56  defines a separator in the form of the blunt surface  58 ′ and the knife cutter is omitted. The blunt surface  58 ′ is used to break the perforated inflation edge illustrated by  FIG. 2 . The blunt surface  58 ′ breaks open the inflation edge  18  as the web moves through the machine to provide the inflation openings into the pouches  12 . 
     A blower  60  is positioned after the cutter  58  or blunt surface  58 ′ in station B. The blower  60  inflates the web pouches as the web moves past the blower. Referring to  FIG. 9 , the web pouches are opened and inflated at station B. The seal edges  38 ,  40  spread apart as indicated by arrows  61  ( FIGS. 7A ,  7 B and  9 ) as the web pouches are inflated. In the embodiment illustrated by  FIGS. 4 and 6 , the frangible connections  29 ,  36  maintain successive pouches substantially aligned as the web is fed to the filling station B. The frangible connections are sufficiently weak that the connection between a pouch that has been opened for inflation and is being inflated at the fill station B and an adjacent, successive (or preceding) pouch will rupture as the pouch at the fill station is inflated. The spreading of the edges  38 ,  40  forms a row of inflated sealed air filled pouches in a ladder configuration and increases the volume of the air that can enter the pouches. The spreading also reduces the stresses imparted to the web adjacent the inflation side edge  18  where it is to be sealed. 
     The inflation seal  42  is formed at station C by a sealing assembly  62  to complete each dunnage unit. In the exemplary embodiment, the inflated volume of the pouches is maintained by continuing to blow air into the pouch until substantially the entire length of the inflation opening  59  is sealed. In the example of  FIGS. 8A ,  8 B and  9 , the blower  60  blows air into a pouch being sealed up to a location that is a short distance D1 from closing position where the sealing assembly  62  pinches the top and bottom layers  14 ,  16  to maintain the inflated volume of the pouches. This distance D1 is minimized to minimize the volume of air that escapes from the inflated pouch before the trailing transverse seal of the inflated pouch reaches the closing position. For example, the distance D1 may be about 0.250 inches or less, to blow air into the inflation opening unit the trailing transverse seal is within 0.250 inches of the closing position. 
     In the examples illustrated by  FIGS. 8A and 8B , the sealing assembly includes a pair of heated sealing elements  64 , a pair of cooling elements  66 , a pair of drive rollers  68 , and a pair of drive belts  70 . In an alternate embodiment, the pair of cooling elements is omitted. Each belt  70  is disposed around its respective heat sealing element  64 , cooling element  66  (if included), and drive roller  68 . Each belt  70  is driven by its respective drive roller  68 . The belts  70  are in close proximity or engage one another, such that the belts  70  pull the web  10  through the heat sealing elements  64  and the cooling elements  66 . The seal  42  is formed as the web  10  passes through first the heated sealing elements  64  and then a heat sink such as the cooling elements. One suitable heating element  64  includes heating wire  80  carried by an insulating block  82 . Resistance of the heating wire  80  causes the heating wire  80  to heat up when voltage is applied. The cooling elements  66  cool the seal  42  as the web  10  is pulled between the cooling elements. One suitable cooling element is an aluminum (or other heatsink material) block that transfers heat away from the seal  42 . Referring to  FIG. 9 , the spreading of the edges  38 ,  40  greatly reduces the stress imparted on the web material at or near the seal  42 . As a result, a much more reliable seal  42  is formed. 
       FIGS. 10-12  show another embodiment of a web  10 . In this embodiment, the spaced apart lines of perforations  26  extending from the inflation edge, as shown in  FIGS. 1-7B  and  9 , is replaced with a modified line of perforations  90 . As best seen in  FIG. 10 , a starting point  89  of the line of perforations  90  begins a distance D2 from the inflation edge  18  and extends away from and generally perpendicular to the inflation edge  18 . As can be seen in  FIG. 10A , in an embodiment in which a frangible connection  21 ′ (also shown in  FIG. 2A ) is offset from the inflation edge  18  by a distance D4, the distance D2 is greater than the distance D4. Hence, in the examples illustrated by  FIGS. 10-12 , the line of perforations  90  extends to a gap forming area  28  and an opposite edge line of perforations  24  extends to the opposite edge. In another embodiment, the gap forming area  28  is not included and the line of perforations  90  extends all the way or nearly all the way to the opposite edge. 
     The distance D2 is selected to prevent the cutter ( FIG. 12 ) from engaging the line of perforations in the exemplary embodiment. Although distance D2 may vary based on the particular cutter implemented, in one embodiment, distance D2 is approximately 0.25 inches to approximately 0.375 inches in length.  FIG. 11  illustrates a row of inflated sealed air filled pouches. The elimination of perforations extending to the inflation edge  18  does not make it substantially harder to separate adjacent sealed air filled pouches in the row  11  of sealed air filled pouches  12 ′ in the exemplary embodiment. The sealed air filled pouches  12 ′ can still be separated by inserting an object or objects, such as a hand or hands, into the gap  13  and pulling one dunnage unit  12 ′ away from an adjacent dunnage unit  12 ′. When the sealed air filled pouches are pulled apart, the thin web of material between the starting point  89  and the inflation edge easily breaks. 
     The process of forming perforations through the top and bottom layers of plastic  14 ,  16 , as the web  10  is formed, may cause the top and bottom layers  14 ,  16  to adhere or be held together at the line of perforations. When the lines of perforations extend all the way to the inflation edge and the cutter  58  cuts on one side of the inflation edge, the cutter will engage each line of perforations. Engagement of the lines of perforations by the cutter may cause the web to bind, wrinkle, bunch up, or gather around the edge of the cutter until the cutter passes the line of perforations and begins cutting the web again. In the embodiment illustrated by  FIGS. 10-12 , engagement of the line of perforations  90  with the cutter is eliminated by beginning the line of perforations  90  a distance D2 away from the inflation edge  20 . As illustrated in  FIG. 12 , the tip of a cutter  58  utilized in opening the inflation edge  20  is positioned a distance D3 past the inflation edge  20  as the edge is opened. The distance D2 that the line of perforations  90  is away from the inflation edge  20  is configured to be greater than the distance D3 to which the tip of a cutter  58  is positioned past the inflation edge  20 . As a result, the cutter  58  will not engage the lines of perforations. Likewise, in the case of the frangible connection  21 ′ shown in  FIG. 10A , the cutter  58  or blunt surface  58 ′ ( FIG. 7B ) that opens the offset frangible connection  21 ′ will not engage the lines of perforations  90 . This eliminates the possibility that the cutter or blunt surface could engage the lines of perforations and cause the web to bunch up or gather around the cutter  58  or blunt surface  58 ′ as the cutter  58  opens the inflation edge. 
     With reference to FIGS.  13  and  13 A- 13 G, other embodiments of the present invention are illustrated in which webs  110  of inflatable sealed air filled pouches  112  are shown. As in the previous embodiments, the webs  110  include a top elongated layer of plastic  114  superposed onto a bottom layer of plastic  116 . The layers  114 ,  116  are connected together along spaced edges, referred to as the inflation edge  118  and the opposite edge  120 . Transverse seals  122  join the top and bottom layers  114 ,  116 . 
     In the examples illustrated by  FIGS. 13 ,  13 B,  13 D,  13 E,  13 F, one or more internal seals  124  define two (2) chambers  126   a ,  126   b  within each pouch  112 . Each of the internal seals  124  seals the layers  114 ,  116  together. In the exemplary embodiment illustrated by  FIG. 13 , embodiment, four (4) of the internal seals  124   a ,  124   b ,  124   c ,  124   d  (collectively  124 ) are circular and faun a staggered pattern, which is described in more detail below. However, other embodiments, including different numbers of the internal seals  124  of other shapes and/or other patterns of the internal seals  124  are also contemplated (See  FIGS. 13B ,  13 D,  13 E, and  13 F). 
     Regardless of the pattern defined by the internal seals  124 , it is to be understood that unsealed portions  130  are defined around and between the internal seals  124   a ,  124   b ,  124   c ,  124   d . Furthermore, unsealed portions  130  also exist between the transverse seal  122   a  and the internal seal  124   a  and between the transverse seal  122   b  and the internal seal  124   d.    
     In the examples illustrated by  FIGS. 13A ,  13 C, and  13 G, one or more internal side connected seals  125  define two (2) chambers  126   a ,  126   b  within each pouch  112 . Each of the side connected seals  125  seals the layers  114 ,  116  together and are connected to a seal  122 . Different numbers of the side connected seals  125  of other shapes and/or other patterns of the internal seals  124  are also contemplated. 
     The dimensions of the webs  110  disclosed by the present application can be selected to accommodate any packaging application. In one non-limiting example, web shown in  FIG. 13  can have the dimensions as shown and described as follows. The inflation edge  118  may be about 16.00 inches from a bottom of the opposite edge  120 . Furthermore, the transverse seal  122   a  may be about 7.53 inches from the transverse seal  122   b . It is contemplated that respective centers of the internal seals  124   b ,  124   d  are about 7.80 inches from the inflation edge  118  along respective axes parallel to the transverse seals  122   a ,  122   b , and that respective centers of the internal seals  124   a ,  124   c  are about 7.80 inches from the opposite edge  120  along respective axes parallel to the transverse seals  122   a ,  122   b . In addition, a center of the internal seal  124   a  is about 0.94 inches from the transverse seal  122   a  and about 1.88 inches from a center of the internal seal  124   b  along a first axis perpendicular to the transverse seals  122   a ,  122   b , the center of the internal seal  124   b  is about 1.88 inches from a center of the internal seal  124   c  along a second axis perpendicular to the transverse seals  122   a ,  122   b , the center of the internal seal  124   c  is about 1.88 inches from a center of the internal seal  124   d  along the first axis perpendicular to the transverse seals  122   a ,  122   b , and a center of the internal seal  124   d  is about 0.94 inches from the transverse seal  122   b  along the second axis perpendicular to the transverse seals  122   a ,  122   b.    
     The unsealed portions  130  around the internal seals  124  provide for fluid communication between the chambers  126   a ,  126   b , even after the pouches  112  are filled with fluid and sealed as discussed above. 
     As illustrated in  FIG. 14 , the staggered pattern of the internal seals  124   a ,  124   b ,  124   c ,  124   d  create respective extensions  130   a ,  130   b ,  130   c ,  130   d  (e.g., “fingers”) that protrude into the chambers  126   a ,  126   b . For example, the internal seal  124   a  creates the extension  130   a  that protrudes into the chamber  126   a , the internal seal  124   b  creates the extension  130   b  that protrudes into the chamber  126   b , the internal seal  124   c  creates the extension  130   c  that protrudes into the chamber  126   a , and the internal seal  124   d  creates the extension  130   d  that protrudes into the chamber  126   b . When the pouch  112  is folded along a fold area  132  created by the pattern of internal seals  124  between the chambers  126   a ,  126   b , the extensions  130  overlap one another to create a cushioned area  134  along the fold area  132 . More specifically, the extension  130   a  overlaps the extension  130   b , the extension  130   b  overlaps the extensions  130   a  and  130   c , the extension  130   c  overlaps the extensions  130   b  and  130   d , and the extension  130   d  overlaps the extension  130   c.    
       FIG. 15  illustrates the pouch  112  of  FIG. 13  partially folded along the fold area  132 .  FIG. 16  illustrates the pouch  112  more completely folded, relative to  FIG. 15 , along the fold area  132 .  FIG. 17  illustrates the pouch  112  more completely folded, relative to  FIG. 16 , along the fold area  132 . With reference to  FIGS. 15-17 , the overlapping extensions  130   a ,  130   b ,  130   c ,  130   d  cooperate to create the cushioned area  134 . 
     As illustrated in  FIG. 17 , the pouch  112  may be folded around a corner  136  of a container  138  (e.g., a box). The cushioned area  134  created by the overlapping extensions  130   a ,  130   b ,  130   c ,  130   d  acts to protect the edge  136  of the container  138  from potential damage caused by an external impact. More specifically, the overlapping extensions  130   a ,  130   b ,  130   c ,  130   d  act to prevent the edge  136  of the container  138  from reaching the fold area  132 . Consequently, the edge  136  is cushioned by the extensions  130   a ,  130   b ,  130   c ,  130   d.    
     Although the internal seals have been describes with reference to the pouch  112  illustrated in  FIG. 13 , it is to be understood that the internal seals described herein may be used with a pouch of any design, including any of the pouch designs disclosed in  FIGS. 1-12  and  13 A- 13 G above. 
     With reference again to  FIG. 13 , the opposite edges  120  of the pouches  112  are curved, rather than straight like the opposite edges  20  illustrated in  FIG. 1 . As discussed above, the term foreshortening refers to the tendency of the length of a pouch side to shorten as the pouch is inflated. The pouch side may become curved as it is shortened. In  FIG. 1 , a radius r 1  from a point P along a central axis  140  to a corner  144  (e.g., an intersection between the opposite edge  20  and the transverse edge  22 ) is longer than a radius r 2  from the point P to an inside center of the opposite edge  20 . The “inside center” refers to a point inside the pouch  12 . 
     As illustrated in  FIG. 13 , to achieve the relatively straighter transverse seals  122   a ,  122   b  when the pouch  112  is inflated, in one embodiment it is contemplated that the opposite edges  120  of the pouches  112  are curved to reduce the amount of curve in the transverse seals  122   a ,  122   b  when the pouches are inflated. For example, the opposite edges  120  are curved away from the inflation edge  118 . In  FIG. 13 , similar to  FIG. 1 , a radius r 3  from a point P along the central axis  140  to a corner  142  is longer than a radius r 4  from the point P to an inside center of the curved opposite edge  120 . The “inside center” refers to a point inside the pouch  12 . However, with reference to  FIGS. 1 and 13 , |r 2 −r 1 |&gt;|r 3 −r 4 | to achieve the relatively straighter transverse seals  122   a ,  122   b  illustrated in  FIG. 13 . In one embodiment, |r 3 −r 4 | is less than a predetermined threshold. 
     With reference to  FIG. 18 , a device  150  is illustrated for separating the web  10  into individual pouches  12  or sets of the pouches  12 . As discussed with reference to  FIG. 1 , the web  10  includes spaced pairs of lines of perforations  24 ,  26  extending through the top and bottom layers  14 ,  16 , and a gap forming area  28  extending between each associated pair of lines of perforations  24 ,  26 . The gap forming area  28  opens to form a gap  13  when the pouches are inflated (see  FIG. 3 ). With reference to  FIGS. 1 and 18 , the sealing assembly  62  includes the pair of heated sealing elements  64 , a pair of cooling elements  66 , a pair of drive rollers  68 , and a pair of drive belts  70 . After passing through the sealing assembly  62 , the top and bottom layers  14 ,  16  of the pouches  12  exit at a point  146 . At this point, the web  10  includes the lines of perforations  24 ,  26  and the gap fouling area  28  between the pouches  12 . 
     After exiting the sealing assembly  62 , the web  10  enters a separation assembly  150 . In one embodiment, the separation assembly  150  includes a first stage  152  and a second stage  154 . The first stage  152  includes rollers  156  and belts  160 ; and the second stage  154  includes rollers  162  and belts  164 . The rollers  156 ,  162  rotate to move the belts  160 ,  164  in the first and second stages, respectively. 
     After the web  10  exits the sealing assembly  62 , the web  10  enters the first stage  152  of the separation assembly  150  at a point  166 . The rollers  156  and the belts  160  move the web  10  through the first stage  152  of the separation assembly  150  until the web  10  exits the first stage at a point  170 . The web  10  then enters the second stage  154  of the separation assembly  150  at a point  172 . The rollers  162  and the belts  164  move the web  10  through the second stage  154  of the separation assembly  150  until the web  10  exits the second stage at a point  174 . 
     During use, a controller  176  is used to maintain the rollers  68 , belts  70  at substantially the same speed as the roller  156  and belt  160  of the first stage  152  and also at substantially the same speed as the roller  162  and belt  164  of the second stage  154 . With the first and second stages  152 ,  154  operating at the same speed as the rollers  68  and belts  70  of the sealing assembly  62 , the web  10  is not separated along the lines of perforations  24 ,  26  to separate a pouch  12  or a set of the pouches  12  from the web  10 . 
     When it is desired to separate an individual pouch  12  or a set of the pouches  12  from the web  10 , the controller  176  varies the speed of at least one of the first and second stages  152 ,  154  of the separation assembly  150 . For example, the controller  176  may cause the roller  156  of the first stage  152  to rotate relatively slower than the roller  162  of the second stage  154  by a predetermined threshold. More specifically, the roller  156  of the first stage  152  may simply rotate slower than the roller  162  of the second stage  154  by the predetermined threshold, or the roller  156  of the first stage  152  may even stop. Therefore, the belt  160  moves relatively slower than the belt  164 . With the web  10  in both the first and second stages  152 ,  154 , the relatively slower moving belt  160  causes a stress at the lines of perforations  24 ,  26  between the first and second stages  152 ,  154 , which results in the web  10  separating (e.g., tearing) at the lines of perforations  24 ,  26 . Once the web  10  is separated, the controller  176  causes the first and second stages  152 ,  154  to return to a speed substantially the same as the rollers  68  and belts  70 . 
     It is to be understood the controller  176  may be operated or programmed to selectively control the speeds of the roller  156  and belt  160  of the first stage  152  and the roller  162  and belt  164  of the second stage  154  to separate the web  10  into individual pouches  12  or sets of pouches  12 . 
     Although the separation assembly  150  is illustrated as including the first and second stages  152 ,  154 , it is to be understood that the separation assembly  150  may only include a single stage or, alternatively, may include three or more stages. 
       FIG. 19  illustrates a side view of another representation of a separation assembly  200  for separating the web  10  into individual pouches  12  or sets of the pouches  12 . 
       FIG. 20  illustrates a front view of the a separation assembly  200 . The web (e.g., a pillow chain) is fed into an infeed  210  (shown in  FIG. 19 ) of the separation assembly  200 . With reference to  FIGS. 1 ,  19 , and  20 , while the first belt section  212  (e.g., corresponding to the first stage  152  in  FIG. 18 ) and the second belt section  214  (e.g., corresponding to the second stage  154  in  FIG. 18 ) travel at a relatively constant speed, the pillow chain advances through the separation assembly  200  at a relatively constant speed. When it is desired to separate a pouch  12  or a set of pouches  12  from the web  10 , the first belt assembly  212  is operated at a slower speed, or even stopped, relative to the second belt assembly  214 . A controller, as discussed above, may be used for controlling the speeds of the first and second belt assemblies  212 ,  214 . The slower relative speed of the first belt assembly  212  causes a stress at the lines of perforations  24 ,  26  between the first and second belt assemblies  212 ,  214 , which results in the web  10  separating (e.g., tearing) at the lines of perforations  24 ,  26 . Once the web  10  is separated, the controller may cause the first and second belt assemblies  212 ,  214  to return to a speed substantially the same. 
     As illustrated in  FIG. 20 , the first and second belt assemblies  212 ,  214  are driven by first and second drives  216 ,  220 , respectively. The controller discussed above can control the speeds of the first and second belt assemblies  212 ,  214  via the first and second drives  216 ,  220 , respectively. The controller receives input from a first sensor  222  positioned behind the first belt assembly  212  and a second sensor  224  positioned behind the second belt assembly  214 . The first sensor  222  is an optical sensor capable of detecting the edges of the gap forming area  28  of each pouch  12  and sending a signal to the controller when an edge is detected. The controller increments a counter for the first edge of each pouch  12  that passes within the field of view of the first sensor  222 , thereby counting the number of pouches  12  that pass by the first sensor  222 . The controller is also capable of calculating the width  39  of each pouch  12  using the timing of the signals from the first sensor  222  and the speed of the first belt assembly  212 . The second sensor  224  is a motion sensor that detects motion in the web  10  of pouches  12  when a chain of pouches is manually separated from the web  10  by the operator when the separation assembly  200  is in manual tear mode. 
       FIG. 21  illustrates a bottom view of the separation assembly  200  shown in  FIGS. 19 and 20 . A web  10  of pouches  12  is shown passing through the separation assembly  200 . To accommodate the different thickness of different types of pouches  12 , the adjustable belt assembly  232  can be moved on supports  236  to adjust the gap  230  between the adjustable belt assembly  232  and the fixed belt assembly  234 . The gap  230  is adjusted such that the belts in the adjustable and fixed belt assemblies  232 ,  234  make enough contact with each pouch  12  in the web  10  to move the web  10  through the separation assembly  200  without damage. Each of the adjustable and fixed belt assemblies  232 ,  234  are comprised of half of the first and second belt assemblies  212 ,  214 , and one each of the first and second drives  216 ,  220  shown in  FIGS. 19 and 20 . 
     The separation assembly  200  can be set by the operator to operate in one of two different modes: dispenser and manual tear. When dispenser mode is selected the controller follows the flow chart diagram in  FIG. 22 . The steps of the dispenser mode are illustrated in  FIGS. 23-26 . Steps A and B are illustrated by  FIG. 23 . In Step A, the operator loads the web  10  of pouches  12  through the infeed  210  (shown in  FIG. 19 ) into the first belt assembly  212 . In Step B, the operator selects the desired number of pouches  12  to be dispensed as a connected chain. Step C is illustrated by  FIG. 24 . In Step C, the separation assembly  200  feeds the web  10  through the first belt assembly  212  and into the second belt assembly  214 . As the web  10  is fed through the first belt assembly  212  the first sensor  222  counts the pouches  12  in the web  10  and the controller uses this information to measure the width  39  of the pouches  12 . Step D is illustrated by  FIG. 25 . After it has counted out the desired number of pouches  12 , in Step D the controller stops the first and second belt assemblies  212 ,  214  so that the last pouch  12  of the desired chain  240  is positioned inside of the second belt assembly  214 , and the separation location  242  is between the first and second belt assemblies  212 ,  214 . The controller accurately positions the web  10  in Step D using the width  39  information calculated in Step C, combined with a known stopping time for the first and second belt assemblies  212 ,  214 . Step E is illustrated by  FIG. 26 . Next, in Step E, the controller directs the second belt assembly  214  to advance while the first belt assembly  212  remains stopped, thereby separating the desired chain  240  from the web  10  at the separation location  242  and dispensing it from the separation assembly  200 . After the desired chain  240  has been dispensed, the controller returns to Step B to await the next selection instruction from the operator. 
     When dispenser mode is selected the controller follows the flow chart diagram shown in  FIG. 27 . The steps of the manual tear mode are illustrated in  FIGS. 28-31 . Steps A′ and B′ are illustrated by  FIG. 28 . In Step A′, the operator loads the web  10  of pouches  12  through the infeed  210  (shown in  FIG. 19 ) into the first belt assembly  212 . In Step B′, the operator selects the desired number of pouches  12  to be manually torn off as a connected chain. Step C′ is illustrated by  FIG. 29 . In Step C′, the separation assembly  200  feeds the web  10  through the first belt assembly  212  and into the second belt assembly  214 . As the web  10  is fed through the first belt assembly  212  the first sensor  222  counts the pouches  12  in the web  10  and the controller uses this information to measure the width  39  of the pouches  12 . Step D′ is illustrated by  FIG. 30 . After it has counted out the desired number of pouches  12 , in Step D′ the controller stops the first and second belt assemblies  212 ,  214  so that the last pouch  12  of the desired chain  240  and the separation location  242  are positioned below the second belt assembly  214  and outside of the separation assembly  200 . The controller accurately positions the web  10  in Step D′ using the width  39  information calculated in Step C′, combined with a known stopping time for the first and second belt assemblies  212 ,  214 . Step E′ is illustrated by  FIG. 31 . Next, in Step E′, the operator manually separates the desired chain  240  from the web  10  at the separation location  242  using his hand or some other tool. When the operator removes the desired chain  240 , the second sensor  224  detects motion in the web  10  that is within the second belt assembly  214  and sends a signal to the controller. Upon receiving this signal from the second sensor  224 , the controller returns to Step C′ and feeds the web  10  forward until another desired chain  240  of pouches in position below the separation assembly  200 , ready to be removed by the operator. 
     Several exemplary embodiments are disclosed by this application. Inflatable webs, machines for sealing inflatable webs, and machines for separating filled and sealed inflated pouches may include any combination or subcombination of the features disclosed by the present application. 
     While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant&#39;s general inventive concept.