Patent Publication Number: US-10787284-B2

Title: Idler roller

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 62/314,209, entitled “Idler Roller” and filed on Mar. 28, 2016, which is herein incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     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 plies 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. 
     Many machines used in the packaging industry operate with numerous rollers some that utilize belts to control the advancement of the film there through. For example, U.S. Pat. No. 8,128,770 discloses a system that utilizes belts and rollers to control the inflation and sealing of cushions. The presence of the belts or other additional components in these machines can make them costly to manufacture and sometimes difficult to use. In another example, U.S. Pat. No. 7,950,433 discloses one roller with a heading element wrapped there around pressed directly against another roller. This sort of system does not allow for adequate cooling of the film before being removed from the machine. As such, an improved inflation and sealing mechanism is desirable in the industry. 
     SUMMARY 
     In accordance with various embodiments, and inflation and sealing device that includes an inflation assembly that inflates with a fluid a cushion cavity disposed between overlapping portions of first and second plies of a film, which plies form a flexible structure. The device also includes a sealing mechanism having a first compression element having a curved surface operable to bend the flexible structure thereabout. The sealing mechanism also includes a second compression element positioned against the first compression element to pinch the flexible structure therebetween at a first pinch area. The sealing device also includes a heating element disposed adjacent the first pinch location to heat the film sufficiently to seal the plies to each other to produce a longitudinal seal as the film is moved past the first pinch area. The sealing device also includes a third compression element positioned against the first compression element to pinch the flexible structure therebetween at a second pinch area downstream of the first pinch area. The first, second, and third compression elements hold the flexible structure against the first compression element along a cooling path between the first and second pinch areas. A surface of the film opposite from the first compression element is substantially free of contact with the sealing mechanism. The film is sufficiently retained against the first compression element to hold the fluid in the cushion cavity while the longitudinal seal cools. 
     In accordance with various embodiments, the first, second, and third compression elements are nip rollers. In one embodiment, the first nip roller has a rotation axis, and the first and second pinch areas are separated by an angle of greater than 30° as measured about the rotation axis. In various embodiments, the first nip roller, the second nip roller and the third nip roller each have approximately a same radius. In another embodiment, the first and second pinch areas are separated by an angle of greater than 60° as measured about the rotation axis. In various embodiments, the first and second pinch areas are separated by an angle of up to 180° as measured about the rotation axis. 
     In accordance with various embodiments, the first nip roller is movable relative to the second nip roller such that the first and second nip rollers can be separated for loading or removing the film from therebetween. The third nip roller is movable relative to relative to at least one of the second nip roller and the first nip roller such that the third nip roller can be separated from at least one of the second nip roller and the first nip roller for loading or removing the film from therebetween. The third nip roller is positioned on a third nip roller lever having a pivot point positioned at a location different than the axis of rotation of the third nip roller, such that rotation of the lever about the pivot point moves the third nip roller toward or away from the first nip roller. The third nip roller lever is spring loaded such that the third nip roller lever biases the third nip roller toward the first nip roller such that the third nip roller is operable to compress the flexible structure against the first nip roller under the force of the spring. The first nip roller is positioned on a lever having a pivot point positioned at a location different than the axis of rotation of the first nip roller, with the pivot point positioned such that rotation of the lever about the pivot point moves the first nip roller toward or away from the second nip roller. The first nip roller lever is spring loaded such that the first nip roller lever biases the first nip roller toward the second nip roller compressing the flexible structure against the second nip roller under the force of the spring. The pivot point is positioned such that rotation of the lever about the pivot point moves the first nip roller generally tangentially relative to the pinch area with the third nip roller. The first nip roller lever engages the third nip roller lever such that as the first nip roller lever rotates moving the first nip roller away from the second nip roller, the first nip roller lever causes the third nip roller lever to rotate such that the third nip roller moves away from the second pinch area. The third nip roller lever includes a notch having a surface that engages the first nip roller lever such that forces from the first nip roller lever against the notch surface causes the third nip roller lever to rotate. The third nip roller axis is positioned between the notch and the third nip roller lever pivot. 
     In accordance with various embodiments, the sealing mechanism is beltless. In accordance with various embodiments, the inflatable-cushion inflation and sealing device also can include a cover that covers one or more of the first, second, or third rollers and provides a slot operable to redirect the flexible structure after the flexible structure exits the second pinch area. 
     In accordance with various embodiments, and inflation and sealing device that includes an inflation assembly that inflates with a fluid a cushion cavity disposed between overlapping portions of first and second plies of a film, which plies form a flexible structure. The device also includes a sealing mechanism a first compression element having a curved surface operable to bend the flexible structure thereabout. The sealing mechanism also includes a second compression element positioned against the first compression element to pinch the flexible structure therebetween at a first pinch area. The sealing mechanism also includes a third compression element positioned against the first compression element to pinch the flexible structure therebetween at a second pinch area downstream of the first pinch area. The sealing mechanism also includes a heating element disposed adjacent to the first compression element and second compression element. The first compression element is adjustable relative to the second compression element and the third compression element is adjustable relative to the first compression element. The first compression element engages the third compression element such that as the first compression element is adjusted away from the second compression element, the third compression element is automatically moved away from the first compression element. 
     In accordance with various embodiments, the first, second, and third compression elements are first, second, and third nip roller assemblies having first, second, and third nip rollers, respectively. The third nip roller is positioned on a third nip roller lever having a pivot point positioned at a location different than the axis of rotation of the third nip roller. The pivot point is positioned such that rotation of the lever about the pivot point moves the third nip roller toward or away from the first nip roller. The third nip roller lever is spring loaded such that the third nip roller lever biases the third nip roller toward the first nip roller such that the third nip roller is operable to compress the flexible structure against the first nip roller under the force of the spring. The first nip roller is positioned on a lever having a pivot point positioned at a location different than the axis of rotation of the first nip roller. The pivot point positioned such that rotation of the lever about the pivot point moves the first nip roller toward or away from the second nip roller. The first nip roller lever is spring loaded such that the first nip roller lever biases the third nip roller toward the second nip roller such that the first nip roller is operable to compress the flexible structure against the second nip roller under the force of the spring. The pivot point is positioned such that rotation of the lever about the pivot point moves the first nip roller generally tangential to the pinch area with the third nip roller. The third nip roller lever includes a notch having a surface that engages the first nip roller lever such that forces from the first nip roller lever against the notch surface causes the third nip roller lever to rotate and the third nip roller axis is positioned between the notch and the third nip roller lever pivot. 
     In accordance with various embodiments, the first, second, and third nip rollers hold the flexible structure against the first nip roller along a cooling path between the first and second pinch areas with a surface of the film opposite from the first compression element substantially free of contact with the sealing mechanism. The film is sufficiently retained against the first compression element to hold the fluid in the cushion cavity while the longitudinal seal cools. In accordance with various embodiments, the sealing mechanism is beltless. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of an uninflated material flexible structure according to an embodiment; 
         FIGS. 2A-D  is a perspective view, front view with covers, front view without covers, and side view, respectively, of the inflation and sealing device in accordance with a first embodiment; 
         FIGS. 3A-C  is a perspective view, front view with covers, and front view without covers, respectively, of the inflation and sealing device in accordance with a second embodiment; 
         FIG. 4A  is a detailed front view without covers of the inflation and sealing assembly in accordance with various embodiments; 
         FIG. 4B  is a front perspective view without covers of the inflation and sealing assembly in accordance with various embodiments; and 
         FIG. 4C  is a front perspective view of the compression mechanism in accordance with various embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is related to protective packaging and systems and methods for converting uninflated material into inflated cushions that may be used as cushioning or protection for packaging and shipping goods. 
     As shown in  FIG. 1 , a multi-ply flexible structure  100  for inflatable cushions is provided. The flexible structure  100  includes a first film ply  105  having a first longitudinal edge  102  and a second longitudinal edge  104 , and a second film ply  107  having a first longitudinal edge  106  and a second longitudinal edge  108 . The second ply  107  is aligned to be overlapping and can be generally coextensive with the first ply  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 plies can be partially overlapping with inflatable areas in the region of overlap. 
       FIG. 1  illustrates a top view of the flexible structure  100  having first and second plies  105 ,  107  joined to define a first longitudinal edge  110  and a second longitudinal edge  112  of the film  100 . The first and second plies  105 ,  107  can be formed from a single sheet of flexible structure  100  material, a flattened tube of flexible structure  100  with one edge having a slit or being open, or two sheets of flexible structure  100 . For example, the first and second plies  105 ,  107  can include a single sheet of flexible structure  100  that is folded to define the joined second edges  104 ,  108  (e.g., “c-fold film”). Alternatively, for example, the first and second plies  105 ,  107  can include a tube of flexible structure (e.g., a flattened tube) that is slit along the aligned first longitudinal edges  102 ,  106 . Also, for example, the first and second plies  105 ,  107  can include two independent sheets of flexible structure joined, sealed, or otherwise attached together along the aligned second edges  104 ,  108 . 
     The flexible structure  100  can be formed from any of a variety of web materials known to those of ordinary skill in the art and as such the flexible structure  100  may also be referred to as a web or web  100  herein. 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 flexible structure  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 flexible structure  100  can include a series of transverse seals  118  disposed along the longitudinal extent of the flexible structure  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 flexible structure  100 . 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 various embodiments, the transverse seals  118  have one or more 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 increase the flexibility of flexible structure  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 plies 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 flexible structure  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 flexible structure. 
     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 plies, 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. 
     While described herein with respect to the flexible structure example shown in the claims, it should be appreciated that other inflatable flexible structures can also be used in conjunction with the other embodiments and examples described herein. 
     Turning now to  FIGS. 2A-3C , an inflation and sealing device  102  for converting the flexible structure  100  of uninflated material into a series of inflated pillows or cushions  120  is provided. As shown in  FIG. 2A , the uninflated flexible structure  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 the material  134 . Alternative structures can be used to support the roll, such as a tray, fixed spindle or multiple rollers. 
     The flexible structure  100  is pulled by a drive mechanism. In some embodiments, intermediate members such as guide rollers can be positioned between roll  134  and the drive mechanism. For example, the optional guide roller can extend generally perpendicularly from a housing  141 . The guide roller can be positioned to guide the flexible structure  100  away from the roll of material  134  and along a material path “B” along which the material is processed. In one example, the guide roller 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 flexible structure  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 flexible structure feed mechanisms in order to guide the flexible structure  100  toward a pinch area  176  which is part of the sealing mechanism  103 . In accordance with various embodiments, as shown in  FIGS. 2-4 , the flexible structure  100  may be pulled from roll  134  directly to the nozzle  140 . While this arrangement may be preferable for simplicity, other arrangements may also be provided. For example, because the flexible structure  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. For example, a nozzle  140  may be at least partially flexible, allowing the nozzle  140  to adapt to the direction the flexible structure  100  approaches as the structure is fed towards and over the nozzle  140 , thereby making the nozzle  140  operable to compensate for or adapt to variations in the feed angle, direction, and other variations that the flexible structure  100  encounters as it is fed towards and over the nozzle  140 . 
     The inflation and sealing device  102  includes an inflation and sealing assembly  132 . Preferably, the inflation and sealing assembly  132  is configured for continuous inflation of the flexible structure  100  as it is unraveled from the roll  134 . The roll  134 , preferably, comprises a plurality of chambers  120  that are arranged in series. To begin manufacturing the inflated pillows from the flexible structure  100 , the inflation opening  116  of the flexible structure  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  FIGS. 2A-3C , preferably, the flexible structure  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 flexible structure  100  is advanced along the material path “E” in a longitudinal direction. The inflated flexible structure  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 pinch area  176 . The flexible structure  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 flexible structure  100  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, as shown for example in  FIGS. 6A and 6D , 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  142   a , and a tip  142 . 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  142   a , or the tip  142 . 
     As shown in  FIG. 4A-B , the side outlet  146  can extend longitudinally along the nozzle base  144  toward a longitudinal distance from the inflation tip  142 . In various embodiments, 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. 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 amounts of air. Although, in other embodiments, the slot outlet  146  can extend downstream past the entry pinch area  176  and portions of the fluid exerted out of the outlet  146  are directed into the flexible structure  100 . As used herein, the terms upstream and downstream are used relative to the direction of travel of the flexible structure  100 . The beginning point of the flexible structure 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 over a portion of the length 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 pinch area  176 . In another example, the slot length may be about half of the distance from the tip  142  to the pinch area  176 . 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 . 
     The flow rate of the fluid through the nozzle  140  is typically about 2 to 15 cfm, with an exemplary embodiment of about 3 to 5 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 of 1100 cfm. 
     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 portion  142   a  which allows the nozzle  140  to be adjustable relative to the travel path “E” of the flexible structure  100 . 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 . The nozzle  140  and inflation assembly may be configured in accordance with other embodiments. 
     The tip of the inflation nozzle can be used to pry open and separate the plies in an inflation channel at the tip as the material is forced over the tip. For example, when the flexible structure is pulled over traditional inflation nozzles, the tips of the traditional inflation nozzles force the plies to separate from each other. 
     A longitudinal outlet may be provided in addition to or in the absence of the lateral outlet, such as side outlet  146 , which may be downstream of the longitudinal outlet and along the longitudinal side of the nozzle wall of the nozzle base  144  of the inflation nozzle  140 . 
     In various embodiments, the inflation nozzle  140  can be positioned horizontally, angled upwards, angled downwards, or in variation in between. 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 direction that accommodates the angle at which the roll  134  dispenses the flexible material  100  and in which the sealing assembly  134  processes the flexible material  100 . The inflation nozzle base  144  and its longitudinal axis X may be aligned tangentially to the sealing assembly. The nozzle  140  may be flexible, allowing for variations in the approach of the flexible structure  100 . 
       FIGS. 2A-4B  illustrate a side view of the inflation and sealing assembly  132 . 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 housing plate  184  includes a sealing and inflation assembly opening  184   a  as shown in  FIG. 4A . The fluid source is connected to and feeds the fluid inflation nozzle conduit  143 . The flexible structure  100  is fed over the inflation nozzle  140 , which directs the flexible structure to the inflation and sealing assembly  132 . 
     The flexible structure  100  is advanced or driven through the inflation and sealing assembly  132  by a drive mechanism  160 . The drive mechanism  160  includes one or more devices operable to drive the flexible structure through the system. For example, the drive mechanism includes one or more motor-driven rollers operable to drive the flexible material  100  in a downstream direction along a material path “E”. One or more of the rollers or drums are connected to the drive motor such that the one or more rollers drive the system. In accordance with various embodiments, the drive mechanism  160  drives the flexible structure  100  without a belt contacting the flexible structure. In one example, the entire system is beltless. In another example, the system has a belt on drive elements that do not come into contact with the flexible structure  100 . In another example, the system has a belt on some drive elements but not others. 
     In accordance with various embodiments, the sealing assembly  132  includes the drive mechanism  160 . The drive mechanism  160  includes at least one compression element  162 . The at least one compression element  162  may include a curved surface  162   a  that is operable to bend the flexible structure about a bend axis  162   b . The drive mechanism  160  includes another compression element  161  that is positioned adjacent to the compression element  162 . The compression element  161  is positioned relative to the compression element  162  such that the two compression elements  161 ,  162  together are operable to receiving the flexible material  100  at a pinch area  176 . The pinch area  176  is defined by the area in which the compression element  161  and the compression element  162  are positioned against the flexible structure  100  to pinch the flexible structure  100  there between. 
     The drive mechanism  160  can also include another compression element  163 . The compression element  163  is also positioned adjacent to the compression element  162 . The relationship between the compression element  163  and the compression element  162  is such that the two compression elements  162 ,  163  form a second pinch  178  area in which the compression element  163  and the compression element  162  contact the contact and apply pressure to the flexible material  100 . 
     In accordance with various embodiments, the drive system forms a cooling path that is disposed downstream of the first pinch  160 . In one example, the cooling path is defined by the curved surface  162   a . The peripheral area of the curved surface  162   a  along the compression element  162  forms a contact area that engages the flexible material directly. As discussed in more detail below, in some embodiments, the peripheral area is cylindrical and, accordingly, the peripheral area is the outer circumferential area of the cylinder. In other embodiments, the peripheral area is the outer area of the surface of the shape defining the compression element  162 . In accordance with the various embodiments, the compression element  162  forms a path between pinch area  176  and pinch area  178  that allows the newly formed longitudinal seal  112  on the flexible material  100 . The longitudinal seal  112  is formed by a heating assembly  400  that is a part of sealing assembly  132 . The pinch area  178  holds the flexible structure sufficiently tight against the curved surface  162   a  of the compression element  162  to retain the fluid within the chamber  120  as the longitudinal seal  112  cools. Holding the longitudinal seal  112  against the cooling zone limits the stretching and deformation caused by the air pressure within the inflated chamber at the longitudinal seal  112 . Absent the holding pressure caused by the pinch area  176  and  178  against the cooling zone along curved surface  162   a , the effectiveness of the longitudinal seal  112  would be reduced due to the air pressure within the inflated chamber. In accordance with various embodiments, the cooling zone is sufficiently long to allow sufficient cooling of the longitudinal seal  112  to set in the seal such that the air pressure within the inflated chamber  120  does not stretch or deform the longitudinal seal  112  beyond the longitudinal seal  112 &#39;s ability to hold the air pressure therein. If the cooling zone is not sufficiently long, the longitudinal seal does not properly set. If the angle between the pinch area  176  and the pinch area  178  is too far the inflated material will wrap back on itself. Thus the location of the compression element  163  and the compression element  161  relative to one another as measured around the curved surface  162   a  should be a position that produces a seal sufficient to hold the chamber pressure without allowing the flexible material to interfere with itself. 
     In accordance with various embodiments, the surface of the film that is not in contact with the curved surface  162   a  is free of contact with other drive components of the inflation and sealing device in the cooling zone. Such a configuration allows heat to escape from this side of the material. For example, the free surface is free of contact with rollers, belts, heating elements, or the like. In some of these particular embodiments having a free surface, some incidental contact may be made between the free surface and a guide element such as a cover, however a snug interface between the film and the surface  162   a  through the cooling zone can minimize this. 
     In accordance with various embodiments, the pinch area  178  is located at an angle that is greater than 15° from the pinch area  176  as measured around axis  162   a . In such an embodiment, the curvatures of the compression elements  161  and  163  are smaller than the radius of the curved area  162   a  of compression element  162 . In various embodiments, the pinch area  178  is located at an angle that is at least or greater than 60° from the pinch area  176  as measured around axis  162   a . In such an embodiment, the radius of the curvature of the compression elements  161  and  163  can be approximately the same radius as the curved area  162   a  of compression element  162 . In other examples of this embodiment, the radius of the curvature of the compression elements  161  and  163  can be greater than the radius of the curved area  162   a  of compression element  162 . In accordance with various embodiments, the pinch area  178  is located between 30° and 180° from the pinch area  176  as measured around axis  162   a . In such embodiments, the curved surface  162   a  is cylindrical between the pinch area  176  and  178  with a radius of between about 1 and ½ cm and 3 cm. In a particular example, the pinch area  178  is located about 90° from the pinch area  176  as measured around axis  162   a . In this example, the radius of curved surface  162   a  or the cooling zone is about 3¼ cm. The outer surface of the compression element  162  is preferable smooth and continuous. In other embodiments, however, the outer surface may be conical, concave, or have a contoured surface. 
     In each of the above embodiments and examples, it should be appreciated that the pinch areas  176  and  178  are defined by the positions of the compression elements  161 ,  162  and  163  relative to each other. As such, the positions between compression elements  161  and  163  can be similarly defined by the angles there between such that those positions create the relative locations of the pinch points discussed above. 
     In accordance with various embodiments, one or both of the compression elements  161  and  163  also have curved surfaces. In accordance with one example, all three compression elements  161 ,  162 , and  163  are cylindrical. In a more particular example, one or more of the compression elements  161 ,  162 , and  163  are rollers. These rollers can be nip rollers that pinch the flexible material  100 . As such, in accordance with various examples, the compression element  161  can be a roller that forms the first pinch area  176  with the compression element  162  that is also a roller having an axis of rotation about the axis  162   b . Similarly, in the same example, the compression element  163  can be a roller that forms the second pinch area  178  with the compression element  162  that is also a roller having an axis of rotation about the axis  162   b . Under this example, the nip rollers  161  and  162  can pinch the flexible material  100  at pinch area  176  and drive the material to the pinch area  178  between nip rollers  163  and  162  while maintaining direct contact between the flexible material  100  and the outer circumference  162   a  of the nip roller  162 . 
     In accordance with various embodiments, each of the compression elements may be variously adjustable relative to the other compression elements. Thus, the compression element  161  can be adjustable relative to at least one of compression elements  162  or  163 . The compression element  162  can be adjustable relative to at least one of compression elements  161  or  163 . The compression element  163  can be adjustable relative to at least one of compression elements  161  or  162 . In a preferred embodiment, compression element  162  is stationary with one or more of compression elements  161  and  163  adjustable relative to the compression element  162 . For example, the compression element  161  is adjustable relative to the compression element  162 . In another example, the compression element  163  is adjustable relative to the compression element  162 . In a third example, both the compression elements  161  and  163  are adjustable relative to compression element  162 . The adjustment of the various compression elements relative to one another is such that the adjustment forms a gap between each of the compression elements in an open state and removes the gap or forms a sufficiently small gap in a closed state so that the various compression elements pinch the flexible material  100  there between. 
     In accordance with various embodiments, one or more of the various compression elements  161 ,  162 , and  163  can include an adjustment mechanism that allows the adjustment discussed above between the various compression elements  161 ,  162 , and  163 . The adjustment of the various compression elements  161 ,  162 , and  163  relative to one another may be accomplished manually, mechanically, or a combination of the two. This adjustment can be rectilinear, curvilinear, or include any combinations of paths that allow controlled movement between the various compression elements. 
     In various examples and as illustrated in  FIGS. 4A-C , the compression element  163  is positioned on an adjustment mechanism  165 . The adjustment mechanism  165  is a device that is operable to move the compression element  163  toward or away from another compression element such as compression element  162 . This adjustment creates or decreases the gap discussed above so that the flexible material  100  can be fit into the gap and then pinched between compression elements  163  and  162 . In various examples, the adjustment mechanism  165  includes a lever  510 . The lever  510  is pivotable about an axis  512 . For example, the lever  510  includes a hole that mounts on a stud  516 , with the stud  516  and the lever hole being coaxial at axis  512 . The compression element  163  mounts coaxial with a second axis  163   b  positioned at a first distance from axis  512 . The second axis  163   b  may be defined by the stud  514  around which the compression element  163  may pivot in embodiments in which the compression element  163  pivots. In accordance with various embodiments, the axis  512  is positioned such that rotation of the lever  510  about the axis  512  moves the compression element  163  generally radial to the compression element  162  at the pinch area  178 . 
     In accordance with various embodiments, the compression element  163  is biased toward the compression element  162 . For example, a biasing mechanism  520  biases the adjustment mechanism  165  toward the compression element  162  such that the compression element  163  is biased toward the compression element  162 . In one particular example, the biasing mechanism  520  is a torsion spring positioned around stud  516  with a first end of the torsion spring engaging a stud  518  extending from the housing (e.g. the housing plate  184 ) and the second end of the torsion spring  520  engaging the lever  510 . The torsion spring  520  is positioned in such a manner that the torsion spring  520  forces the end of the lever opposite the stud  516  toward the compression element  162 . With the compression element  163  positioned on the end of the lever opposite the stud  516 , the compression element  163  pivots about the axis  512  at the stud  516  and is forced against the compression element  162 . The force exerted by the spring causes the compression element  163  and the compression element  162  to compress the flexible material there between under the force of the spring. While this example and the illustrated example in  FIGS. 4A-C  are directed to a torsion spring, it may be appreciated that other biasing mechanisms may be used as well including coil springs, extension springs, a flexible lever, counterweights, or any device known or developed in the art. 
     In various examples and as illustrated in  FIGS. 4A-C , the compression element  162  is also or alternatively positioned on an adjustment mechanism such as adjustment mechanism  164 . The adjustment mechanism  164  is a device that is operable to move the compression element  162  toward or away from another compression element such as compression element  162 . This adjustment creates or decreases the gap discussed above so that the flexible material  100  can be fit into the gap and then pinched between compression elements  162  and  161 . In various examples, the adjustment mechanism  164  includes a lever  530 . Lever  530  can be made of a single integral structure or multiple connected structures such as those shown in  FIGS. 4A-C . The lever  530  is pivotable about an axis  532 . For example, the lever  530  includes a hole at a first end that mounts on a stud  536 , with the stud  536  and the lever hole being coaxial at axis  532 . The compression element  162  mounts coaxial with a second axis  162   b  positioned at a first distance from axis  532 . In various embodiments, the compression element  162  does not mount directly to the lever  530  (either section  530   a  or  530   b ) but instead is positioned relative to the lever  530  at clearance  542 . In one example, fasteners  544  mount a drive motor  332  (or gearbox, mounting bracket or the like) to the lever  530  and the compression element  162  is mounted to the drive motor  332  along the drive axis  162   b . In accordance with various embodiments, the axis  532  is positioned such that rotation of the lever  530  about the axis  532  moves the compression element  162  generally tangential to the compression element  163  at the pinch area  178  and generally radially to the compression element  161  at the pinch area  176 . 
     In accordance with various embodiments, the compression element  162  is biased toward the compression element  161 . For example, a biasing mechanism  540  biases the adjustment mechanism  164  toward the compression element  161  such that the compression element  162  is biased toward the compression element  161 . In one particular example, the biasing mechanism  540  includes one or more extension springs positioned between a stud  539  and a stud  538 . The stud  538  is mounted extending from the housing (e.g. the housing plate  184 ) and the stud  539  is mounted extending from the lever  530 . In this way, the extension springs bias the stud  538  toward the stud  539 . The extension springs  540  are positioned in such a manner that extension springs  540  forces the end of the lever opposite the stud  536  toward the compression element  161 . With the compression element  162  positioned on the end of the lever  530  opposite the stud  536 , the compression element  162  pivots about the axis  532  at the stud  536  and is forced against the compression element  161 . The force exerted by the biasing member  540  causes the compression element  162  and the compression element  161  to compress the flexible material  100  there between under the force of the biasing member  540 . While this example and the illustrated example in  FIGS. 4A-C  are directed to extension springs, it may be appreciated that other biasing mechanisms may be used as well including coil springs, torsion springs, a flexible lever, counterweights, or any device known or developed in the art suitable to biasing a mechanical system. 
     In accordance with one embodiment, the lever  530  may include bracket  530   a  and bracket  530   b . The two brackets are connected to one another such that bracket  530   a  pivots about axis  532  behind plate  184 , while bracket  530   b  pivots with at least one surface extending through or approximately flush with the plate  184 . For example, plate  184  may have an opening  531  extending there through. Bracket  530   b  may extend partway through this opening  531  or all the way through the opening  531 . In a preferred embodiment, the front surface of bracket  530   b  is approximately flush with the front surface of plate  185  such that features extending from the front surface of bracket  530  extend from a surface that is generally in the same plane as features extending from the front surface of plate  185 . It may also be appreciated that lever  530  may be made with a single integrally formed lever with different front surfaces to operate in the manner described herein. In other embodiments, lever  530  may operate entirely behind, in front of, or in the absence of plate  185 . 
     In accordance with various embodiments, the adjustment mechanism  164  and the adjustment mechanism  165  may be engaged with each other such that when one adjustment mechanism is moved to create a gap or decrease a gap between compression elements, then the other adjustment mechanism is similarly moved to create a gap or decrease a gap between the compression elements. For example, as shown in  FIG. 4C , lever  510  includes a concave notch  522  formed in the end of the lever opposite the pivot axis  512 . One side of the notch  522  includes a ramp  524 . The notch is sized sufficiently to allow a stud  548  to enter into the concave portion of the notch  522  and engage the ramp  524 . In one example, the axis  163   b  is positioned between the notch  522  and the pivot axis  512 . In accordance with various embodiments, the stud  548  extends from the lever  530  on an end of the lever opposite the pivot axis  532 . As shown in  FIG. 4C , as lever  530  is rotated clockwise, the stud  548  engages the ramp  524  creating a force in the lever  510  that would cause the lever to rotate clockwise as well. As the force that causes the lever  530  to rotate clockwise is released, both lever  530  and  510  are biased by their biasing members back to their original biased position. In this manner, when a user rotates lever  530 , the pinch areas  176  and  178  between their respective compression elements are released, forming gaps at these pinch areas. The gaps allow the flexible material  100  to be inserted or removed from the drive mechanism  160 . It should be appreciated that the engagement between adjustment mechanisms  165  and  164  can be reversed such that adjustment mechanism of mechanism  165  automatically causes adjustment of mechanism  164 , just the opposite of what is described above. 
     In accordance with various embodiments, one or more of the compression elements may be nip rollers as discussed above. Each of the nip rollers may be directly driven by a motor. In one example, nip roller  162  is directly driven by motor  332 . In one example, nip roller  161  is directly driven by motor  330 . In one example, both nip rollers  161  and  162  are directly driven by motors  330  and  332 , respectively. In various embodiments, nip roller may be driven alone, in combination with nip roller  16 , in combination with nip roller  162 , or in combination with both nip rollers  161  and  162 . In other embodiments, one motor may drive one or more of the nip rollers via a transmission such as a timing belt. 
     In accordance with various embodiments, the inflation and sealing device  102  may include one or more covers (e.g.  181  and  182 ) over the inflation and sealing assembly  132 . The covers (e.g.  181  and  182 ) can be operable to redirect the flexible structure after the flexible structure exits the second pinch area  178 . For example, the covers include a deflection surface  183  that contacts the flexible material  100  as it exits the pinch area  178  and separates the flexible material  100  from the compression elements  162  and  163 , redirecting the flexible material  100  in any desired direction. The cover may be a harder material than the rollers and sufficiently smooth and continuous to have relatively little engagement or adhering tendency with the flexible material  100 . 
     When viewed from the side, such as in  FIG. 2D , in a transverse direction extending between separate portions of compression element  161 , the heating assembly  400  is positioned transversely between the nozzle  140  and the chambers  120  being inflated to seal across each of the transverse seals. Some embodiments 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 placements of the flexible structure and lateral positioning of the inflation nozzle and sealing assembly can be used. 
     The heating assembly  400  is positioned adjacent to one or more compression elements  161  and  162 , which, as discussed in various embodiments herein, can be driven via a motor or similar motivational source. After inflation, the flexible structure  100  is advanced along the material path “E” towards the pinch area  176  where it enters the sealing assembly  103 . The pinch area  176  is disposed between adjacent compression elements  161  and  162 . The pinch area  176  is the region in which the first and second plies  105 , 107  are pressed together or pinched to prevent fluid from escaping the chambers  120  and to facilitate sealing by the heating assembly  400 . 
     The heating assembly  400  may include a heating element  410  disposed adjacent to the pinch location to heat the pinch area  176 . In a preferred embodiment, the heating element  410  is located at the pinch area  176 . While in the various embodiments disclosed herein the compression elements adjacent to the pinch area  176  may roll, in one embodiment the heating element  410  is a stationary heating element. However, in other embodiments the heating element  410  may move with the compression elements, be stationary with the compression elements, or move relative to the movement of the compression elements. As indicated above, the pinch area  176  is the area wherein the compression elements  161  and  162  are in contact with each other or with the flexible material  100 . The compression elements  161  and  162  have sufficient tension to tightly pinch or press the plies  105 , 107  together. This compression may also bias the plies  105 ,  107  against the heating assembly  400 . During, before, or after being fed through the pinch area  176 , the first and second plies  105 , 107  are sealed together by the heating assembly  400  and exit the pinch area  176 . The heating element  410  can be formed of thermocouples, which melt, fuse, join, bind, or unite together the two plies  105 , 107 , or other types of welding or sealing elements. In a preferred embodiment, the heating element  410  is stationary. In other embodiments, the heating assembly may be a roller with the heating element  410  being movable. In other embodiments, the heating assembly may include a heated belt operable to form a seal. For example, the belt could wrap around one or two of the compression elements. The belt could also avoid contact in the cooling zone of the seals. 
     Preferably, the flexible structure  100  is continuously advanced through the sealing assembly  103  along the material path “E” and past the heating assembly  400  at an area  176  to form a continuous longitudinal seal  170  along the flexible structure  100  by sealing the first and second plies  105 ,  107  together. The flexible structure  100  exits the pinch area  176 , maintaining contact with the compression element  162 . The flexible structure  100  continues along the surface of the compression element  162  to a second pinch area  178  that is the area disposed downstream of the first pinch area  176  as shown in  FIGS. 2A-D . The sealing area  174  is the area proximal to the first pinch area  176  in which the flexible structure  100  is being sealed by the heating assembly  400 . The longitudinal seal  112  is shown as the phantom line in  FIG. 1 . Preferably, the longitudinal seal  112  is disposed a transverse distance from the first longitudinal edge  102 , 106 , and, most preferably, the longitudinal seal  112  is disposed along the mouths  125  of each of the chambers  120 . 
     In the preferred embodiment, the heating assembly  400  and one or more of the compression elements  161 ,  162  cooperatively press or pinch the first and second plies  105 , 107  at the first pinch area  176  against the heating assembly  400  to seal the two plies together. The sealing assembly  103  may rely on pressure from compression element  162  against the heating assembly  400  to sufficiently press or pinch the plies  105 , 107  there between. In accordance with various embodiments, the compression elements  161 ,  162 , and/or  163  include a flexible resilient material that allows for the pressure between the compression elements and the flexible structure  100  to control the positions of the flexible structure. In various embodiments, the outer surface of the compression elements may be an elastomeric material. For example, the outer surface of the compression elements can be a high temperature shore A 45 durometer silicone rubber with about a ¼″ thickness. Other materials or thickness may also be used. For example, one or more of the compression elements may have a low friction outer surface such as polytetrafluoroethylene or similar polymers or low friction materials. 
     In the embodiment shown in  FIGS. 2A-D , the flexible structure  100  enters the sealing assembly  103  at the first pinch area  176  at a downward angle. Although in other embodiments, the flexible structure  100  may enter the sealing assembly  103  at the pinch area  176  that is at an alternate angle relative to the horizontal. For example,  FIGS. 3A-C  illustrate the path into the pinch area  176  to be much more horizontal. Additionally, the flexible structure  100  exits the sealing assembly  103  at an angle sloped upward with respect to the horizontal so that the flexible structure  100  is exiting facing upwards toward the user. (See  FIGS. 2A-D .) Although, horizontal and downward departures are also contemplated herein, such as those shown in  FIGS. 3A-C . 
     In accordance with various embodiments, the inflation and sealing assembly  132  may further include a cutting assembly  300  to cut the flexible structure. The cutting assembly  300  may cut the first and second plies  105 , 107  between the first longitudinal edge  101  and mouth  125  of the chambers. In some configurations, the cutting assembly  300  may cut the flexible structure  100  to open the inflation channel  114  of the flexible structure  100  and remove the first and second plies  105 , 107  from the inflation nozzle  140 . 
     As illustrated in  FIG. 4B , the cutting assembly  300  can include a cutting device or cutting member, such as a blade  310  with a cutting edge  312 , and a cutting tray  320  that holds the blade  310 . Preferably, the cutting member is mounted on the tray  320 . In other embodiments, it&#39;s appreciated that a cutting tray  320  can be omitted, and other suitable mechanisms can be used to position the blade  310  adjacent the inflation nozzle  140 . Preferably, the cutting member is sufficient to cut the flexible structure  100  as it is moved past the edge along the material path “E”. In the various embodiments, the blade  310  or knife includes a sharp cutting edge  312  and a tip  314  at the distal end of the blade  310 . In the embodiment shown, the cutting edge  312  is preferably angled upward toward the inflation nozzle  140 , although other configurations of the cutting edge  312  can be used. 
     As shown in  FIG. 4B , the cutting tray  320  holds the blade  310 . This may be done magnetically, with a fastener, or by any other method known. In various embodiments, the cutting assembly  300  may be a fixed assembly or a movable one such as those described in U.S. application Ser. No. 13/844,658. The blade  310  may engage slot  211  on the nozzle base  144 . This engagement may position the blade  310  relative to the nozzle base  144  such that, as the flexible structure  100  slides over the nozzle base  144 , the flexible structure engages the blade  310  and is cut thereby. It may be appreciated that other cutting systems may be utilized with the disclosure provided herein; although the cutting assembly  300  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 various separate embodiments or combinations of embodiments described herein can also be used on other types of film handling devices and in inflating and sealing devices. An example is disclosed in 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. 
     Having described several embodiments herein, it will be recognized by those skilled in the art that various modifications, alternative constructions, and equivalents may be used. The various examples and embodiments may be employed separately or they may be mixed and matched in combination to form any iteration of the alternatives. Additionally, a number of well-known processes and elements have not been described in order to avoid unnecessarily obscuring the focus of the present disclosure. Accordingly, the above description should not be taken as limiting the scope of the invention. Those skilled in the art will appreciate that the presently disclosed embodiments teach by way of example and not by limitation. Therefore, the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method and system, which, as a matter of language, might be said to fall there between.