Patent Publication Number: US-2018037389-A1

Title: Films with stress relief intra-chamber seals

Description:
RELATED APPLICATIONS 
     The present application is a continuation of and claims priority to U.S. patent application Ser. No. 14/630,594 filed Feb. 24, 2015, which in turn claims priority to U.S. Patent Application Nos. 61/944,515, filed Feb. 25, 2014; 62/077,815, filed Nov. 10, 2014; and 62/103,504, filed Jan. 14, 2015, the disclosures of which are all incorporated herein by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed to flexible structures that may be inflated and used as cushioning or protection for packaging and shipping. 
     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. 
     Such film configurations can be stored in rolls or fan-folded boxes in which adjacent inflatable cushions are separated from each other by perforations. During use, a film configuration is inflated to form cushions and adjacent cushions or adjacent stands of cushions are separated from each other along the perforations. 
     A variety of film configurations are currently available. Many of these film configurations include seal configurations that tend to waste material, inhibit separation of adjacent inflated cushions, and/or form inflated cushions that are susceptible to under-inflation or leakage, thereby inhibiting utility. 
     The films are typically inflated by being pulled from a bulk quantity of the film and passed over or proximal to a nozzle. The nozzle blows air in between the films forming cushions. Heat is then used to bind two plies of the film together forming a seal which limits air from escaping. Frequently the films are poorly aligned or have too much freedom (e.g. slack) to be efficiently delivered to the nozzle for inflation. Additionally, due to the heat and pressures used in the process, the films may stick to machine surfaces or the plies may be pulled apart while still hot and exiting the mechanism. 
     SUMMARY 
     In one embodiment, the present disclosure relates generally to an inflatable flexible structure. The inflatable flexible structure may comprise a first film ply. The inflatable flexible structure may comprise a second film ply that is sealed to the first ply to define an inflation chamber therebetween that is inflatable with a fluid and operable to contain the fluid. The inflatable flexible structure may comprise an interior seal disposed within the inflation chamber attaching the first and second plies together, the interior seal including a perimeter seal that encloses an inner portion in which the first and second plies are unattached from one another. 
     In various embodiments, the perimeter seal may entirely enclose the inner portion, separating the inner portion from the inflation chamber. The interior seal may be disposed within the inflation chamber. The interior seal may be disposed entirely within the inflation chamber. The interior seal may include a first elongated portion extending from the perimeter seal. The interior seal may include another perimeter seal. The first elongated portion may extend from the perimeter seal to the other perimeter seal. The interior seal may include an intersection between the perimeter seal and the elongated portion, such that the intersection has three leg portions which are part of the perimeter seal and the elongated portion, the interior seal having an increased width at the intersection compared to the perimeter seal and elongated portion, thereby forming a gusset that resists localized stresses in the sealed film plies. The interior seal may include a second intersection between the perimeter seal and a second elongated portion, such that the second intersection has three second leg portions which are part of the perimeter seal and the second elongated portion, the interior seal having an increased width at the second intersection compared to the perimeter seal and second elongated portion, thereby forming a second gusset that resists localized stresses in the sealed film plies. 
     In various embodiments, the first elongated portion may extend from the perimeter seal to a second perimeter seal, and wherein the second elongated portion extends from the perimeter seal to a third perimeter seal. The inner portion may be at least 10 times wider than the elongated portion. The inflatable flexible structure may include a plurality of said interior seals. The first and second plies may be sealed to one another to define a plurality of inflation chambers therebetween, the plurality of inflation chambers including the inflation chamber and a second inflation chamber. The second inflation chamber may include a second interior seal attaching the first and second plies together. The second interior seal may include a second perimeter seal that encloses a second inner portion in which the first and second plies are unattached from one another. The inner portion may be configured to remain uninflated when the inflation chamber is inflated with the fluid. The first and second plies may be heat sealed together to form the interior seal. The first and second plies may be sealed together with an adhesive to form the interior seal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-D  are schematics of various embodiments of flexible structures as used in conjunction with an inflation and sealing device; 
         FIG. 1E  is a partial view showing an interior seal of  FIG. 1C  shown along view II-II; 
         FIG. 1F  is a partial view showing an interior seal of  FIG. 1C  shown along view III-III; 
         FIG. 2  is perspective view of an inflation and sealing device in accordance with various embodiments; 
         FIG. 3  is a perspective, exploded view thereof; 
         FIG. 4  is a top, right-side view as seen along axis Y of a material support thereof; 
         FIG. 5  is a right-side view of a partially assembled system thereof; 
         FIG. 6  is a front view of the partially assembled device of  FIG. 5 ; 
         FIG. 7  is a perspective, exploded view of a material support and brake of the device of  FIG. 2 ; 
         FIG. 8  is a right-side view of the material support and brake of the device of  FIG. 2 ; 
         FIG. 9  is a right-side view of a sealing mechanism of the device of  FIG. 2 ; 
         FIG. 10  is a front, right perspective view thereof; 
         FIG. 11  is a front, cross-sectional view of post-sealing control elements taken along line XI-XI of  FIG. 9 ; and 
         FIGS. 12A-B  are a perspective view of a film structure that forms a container. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is directed to flexible structures that may be inflated and used as cushioning or protection for packaging and shipping. Specifically, mechanisms prior to sealing and inflation and mechanisms post-sealing and inflation may improve the overall efficiency and speed of the process of forming the cushions. Prior to sealing and inflation, the system may include a material support element which better stores, controls, and delivers the material to the sealing and inflation mechanisms. After the sealing and inflation of the material, material control elements may better direct the material out of the system without damaging the seal or failing to release the heater material from the contact surfaces. 
     Illustrative embodiments will now be described to provide an overall understanding of the disclosed apparatus. Those of ordinary skill in the art will understand that the disclosed apparatus can be adapted and modified to provide alternative embodiments of the apparatus for other applications, and that other additions and modifications can be made to the disclosed apparatus without departing from the scope of the present disclosure. For example, features of the illustrative embodiments can be combined, separated, interchanged, and/or rearranged to generate other embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure. 
       FIGS. 1A-1D  illustrate schematics of various embodiments of flexible structures. The flexible structures may be formed in a variety of manners such as flexible structure  1040  shown in  FIG. 1A , flexible structure  1042  shown in  FIG. 1B , flexible structure  1044  shown in  FIG. 1C , or flexible structure  1046  shown in  FIG. 1D . The flexible structure, such as a multi-ply web  100  of film, for inflatable cushions is provided. The web includes a first web film layer, or ply,  105  having a first longitudinal edge  102  and a second longitudinal edge  104 , and a second web film layer, or 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  (as shown in  FIGS. 1A-1D ), i.e., at least respective first longitudinal edges  102 , 106  are aligned with each other and/or second longitudinal edges  104 , 108  are aligned with each other. In some embodiments, the layers, or plies  105 ,  107 , can be partially overlapping with inflatable areas in the region of overlap. The plies  105 ,  107  may be 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 web material, a flattened tube of web material with one edge slit, or two sheets of web material. For example, the first and second plies  105 , 107  can include a single sheet of web material that is folded to define the joined second edges  104 , 108  (e.g., “c-fold film”). Alternatively, for example, the first and second plies  105 , 107  can include a tube of web material (e.g., a flatten tube) that is slit along the aligned first longitudinal edges  102 , 106 . Also, for example, the first and second plies  105 , 107  can include two independent sheets of web material joined, sealed, or otherwise attached together along the aligned second edges  104 ,  108 . 
     The web  100  can be formed from any of a variety of web materials known to those of ordinary skill in the art. Such web materials may include ethylene vinyl acetates (EVAs), metallocenes, polyethylene resins such as low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and high density polyethylene (HDPE), and blends thereof. Other materials and constructions can be used. The disclosed web  100  can be rolled on a hollow tube, a solid core, or folded in a fan folded box, or in another desired form for storage and shipment. 
     As shown in  FIGS. 1A-D , the web  100  can include a series of transverse seals  118  disposed along the longitudinal extent of the web  100 . Each transverse seal  118  extends from the longitudinal edge  112  towards the inflation channel  114 , and in the embodiment shown, toward the first longitudinal edge  110 . Each transverse seal  118  has a first end  122  proximate the second longitudinal edge  112  and a second end  124  spaced a transverse dimension d from the first longitudinal edge  110  of the film  110 . A chamber  120  is defined within a boundary formed by the longitudinal seal  112  and pair of adjacent transverse seals  118 . 
     Each transverse seal  118  embodied in  FIGS. 1A-D  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  FIGS. 1A-D , is disposed between the second end  124  of the transverse seals  118  and the first longitudinal edge  110  of the film. The longitudinal inflation channel  114  may 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  110  and second ends  124 . It is appreciated, however, that in other configurations other suitable transverse width D sizes can be used. In some embodiments, the inflation opening  116  includes a one-way valve such as those disclosed in U.S. Pat. No. 7,926,507, herein incorporated by reference in its entirety. 
     The longitudinal seal  112  and transverse seals  118  cooperatively define boundaries of inflatable chambers  120 . In one preferred embodiment, the inflatable chambers  120  may further include one or more interior seals  128 . The interior seals  128  may seal the plies  105 ,  107  to one another at intermediate areas within the chamber  120 . As shown in  FIGS. 1A-D , opposing interior seals  128  may be transversely aligned across the chamber  120 . The interior seals  128  may create bendable lines that allow for a more flexible web  100  that can be easily bent or folded. Such flexibility allows for the film  100  to wrap around regular and irregular shaped objects. 
     As shown in  FIGS. 1A-1F , interior seal  128  may include a perimeter seal  132 , which may enclose an inner portion or seal section in which the first and second plies  105 ,  107  are unattached from one another. The perimeter seal  132  may entirely enclose the inner portion, separating the inner portion from the inflation chamber  120 . For example, the inner portion may be configured to remain uninflated when the inflation chamber  120  is inflated with the fluid. 
     The interior seal  128  may be disposed within the inflation chamber  120 . For example, the interior seal  128  may be disposed entirely within the inflation chamber  120 , and is spaced and unconnected from the boundaries (e.g.,  112 ,  118 ) of the inflation chamber  120  in which the interior seal  128  is disposed. In alternative embodiments, the interior seal  128  may be connected to a portion of the chamber boundary (e.g., a transverse seal  118  or a longitudinal seal  112 ). In cases where the interior seal  128  is a connected directly by a seal to a transverse seal  118 , the interior seal  128  may be configured so that the inner portion/seal section  129  is transversely wider than the connection to the transverse seal  118 , so that there is a pinched region between the wider area of the inner portion  129  and the transverse seal  118 . In cases where the interior seal  128  forms a part of a longitudinal seal  112 , the interior seal  128  may have one or more portions that are substantially wider than the connection to the transverse seal  118 , so that there is a pinched region between the wider area of the inner portion  129  and the transverse seal  118 . 
       FIGS. 1E and 1F  are partial views of  FIG. 1C  shown along view II-II and view III-III, respectively. In accordance with various embodiments, such as those illustrated in  FIGS. 1E and 1F , interior seal  128  may include an elongated portion  131 . The elongated portion  131  may extend transversely across chamber  120 . Additionally or alternatively, the elongated portion  131  may extend longitudinally or in another desired direction within the chamber  120 . In some embodiments, an interior seal  128  may include other features, such as two or more perimeter seals  132  that enclose inner portions  129 , and an elongated portion  131  may extend from one of these features to another, such as between perimeter seals  132 , thus connecting the perimeter seals  132 . For example, the two perimeter seals  132  and the elongated portion  131  may together form a “barbell” shape. As shown in  FIGS. 1C and 1D , in some embodiments, an interior seal  128  may include three perimeter seals  132  that enclose inner portions  129 , with the perimeter seals  132  connected to one another by two elongated portions  131 . Those in the art will appreciate that an interior seal  128  of other embodiments may include additional perimeter seals  132  and elongated portions  131  while remaining within the scope of this disclosure.  FIGS. 1A-1D  show chambers  120  having similar interior seal  128  configurations as illustrative examples of the various structures discussed herein. For example, a web  100  may have a first chamber  120  that has a first interior seal  128  having a first configuration (e.g., having a first number of perimeter seals  132  and a first number of elongated portions  131 ), and a second chamber  120  that has a second interior seal  128  having a second configuration (e.g., having a second number of perimeter seals  132  and a second number of elongated portions  131 ). Also, while  FIG. 1C  shows a chamber  120  having two interior seals  128  having similar configurations, those in the art will appreciate that a chamber  120  may have a plurality of interior seals  128  having various configurations (e.g., having varying numbers of perimeter seals  132  or varying numbers of elongated portions  131 ) while remaining within the scope of this disclosure. The web  100  may include any number of interior seals  128 , having any suitable number of perimeter seals  132  and any suitable number of elongated portions  131  disposed within an inflation chamber  120 . 
     The perimeter seal  132  may enclose an inner portion  129  of the plies  105 ,  107 . Inner portion  129 , defined by the perimeter seal  132 , may have a larger width compared to the width of the elongated portion  131 . For example, the inner portion  129  may be at least 5 times wider than the elongated portion  131 . For example, the inner portion  129  may be at least 10 times wider than the elongated portion  131 . For example, the inner portion  129  may be at least 15 times wider than the elongated portion  131 . A solid seal across inner portion  129  (i.e. where the plies  105 ,  107  are attached) may form a stiffer section of the web  100 . A non-solid seal across inner portion  129  (i.e. where the plies  105 ,  107  are unattached) may be a more flexible web  100 . 
     In order to enclose inner portion  129 , the interior seal  128  may have a transition. The transition can form an intersection between the perimeter seal  132  and the elongated portion  131 , such that the intersection has three leg portions  134   a - c , which are part of the perimeter seal  132  and elongated portion  131 . The interior seal  128  may have an increased width at the intersection compared to the perimeter seal  132  and the elongated portion  131 , to form a gusset  127 . The gusset  127  may resist localized stresses in the sealed film plies  105 ,  107 . The gusset  127  may have a width that is wider than the elongated portion  131 . For example the elongated portion  131  may have a width of J. The gusset  127  may widen from width J to 1½ times wider to 10 times wider. For example the gusset  127  may be 5 times wider. The gusset may then narrow again to width K above and below the transition area. The gusset  127  may widen to the entire width of the transition area and then narrow back to width J as the interior seal  128  continues. The gusset  127  may be concave as viewed from the chamber  120 . This may allow the transition to be gradual or not sharp. The gradual transition may reduce stresses at the inner portion  129 . A sharp transition may be a stress riser such as if the inner portion  129  and the elongated portion formed a 90 degree angle. 
       FIG. 1E  shows a perimeter seal  132  that has two elongated portions  131  extending therefrom. For example, as shown in  FIGS. 1C and 1D , an interior seal  128  can include three perimeter seals  132  extending transversely, and the middle perimeter seal  132  can include first and second elongated portions  131  extending therefrom. The first and second elongated portions  131  may extend substantially collinear to each other, and/or the elongated portions  131  may extend substantially parallel to the transverse seals  118 . As shown in  FIG. 1E , the interior seal  128  may include a second intersection between the perimeter seal  132  and the second elongated portion  131 , such that the second intersection has three second leg portions  134   d - f , which are part of the perimeter seal  132  and the second elongated portion  131 . The interior seal  128  may have an increased width at the second intersection compared to the perimeter seal  132  and the elongated portion  131 , to form a second gusset  127 , which may resist localized stressed in the sealed film plies  105 ,  107 . 
     In accordance with various embodiments, the perimeter seal  128  and/or the inner portion  129  may be circular, oval, triangular, or any other shape. As shown in  FIGS. 1E and 1F , the perimeter seal  128  may be circular and may define an inner portion  129  that is a circle. 
     In accordance with various embodiments, the plies, walls, structures, etc., discussed herein may be sealed together (e.g., to form interior seals  128 , longitudinal seals  110 ,  112 , and/or transverse seals  118 ) to form the described structures with any process such as adhesively bonding, friction, welding, fusion, heat sealing, laser sealing, and ultrasonic welding. In various embodiments, an adhesive suitable to connect separate portions of the materials discussed herein may be utilized. The adhesive may be a pressure sensitive, time dependent, evaluative, radiation sensitive, or other forms of adhesives. For example, the adhesive may be cured by exposing the adhesive to an electromagnetic radiation. The adhesive may be sensitive to electromagnetic radiations in specific areas of the electromagnetic radiation spectrum. For example, the adhesive may be a ultraviolet light (UV) curable adhesive. The adhesives may be applied to the plies, walls, or other structures discussed herein by painting, printing, rolling, etc. An adhesive that is operable to seal the inflation chambers sufficiently to contain gas under shipping pressures may be suitable. These pressures may be those formed by stacking the flexible structure under multiple layers of the shipped product or other environmental pressures on the flexible structure internal or external that would occur during shipping, storage, or use. As discussed herein any of the seals may be made by just heat sealing, just adhesive sealing, both types of sealing, or any other type of sealing. 
     In accordance with various examples, the plies  105 ,  107  may be sealed together forming an interior inflation chamber according to any suitable method. Furthermore, the flexible structure  100  already formed of plies  105 ,  107  may be sealed to itself or another portion of flexible structure  100  in order to form specific structures such as for example container  50  (see  FIGS. 12A-B ). 
     As shown in  FIGS. 12A-B , each separate flexible structure (e.g.  100 ) may be utilized to form a container  50 .  FIGS. 12A-B  show a c-fold structure as one example of forming container  50 . For example, the container  50  may be formed by sealing two separate flexible structures  100 . The container  50  may be structured from any number of sheets of flexible structure  100  forming more than two walls as the various application dictates.  FIG. 12A  illustrates a schematic of the flexible structure being folded in accordance with various embodiments. As discussed above, the flexible structure  100  may be folded along intermittent seal  153 . This intermittent seal may be anywhere and in any number, such that flexible structure  100  may be folded with any number of folds. In various embodiments, the flexible structure  100  may be folded along the centerline as illustrated in the example of  FIG. 12A . Folding the flexible structure  100  in this way may allow the edges  102 , 106  and  104 , 108  to align. With the flexible structure  100  folded, the first wall and the second wall may be sealed along a plurality of seals. For example, as illustrated in  FIG. 12B , these seals may include one or more of top seal  145 , external longitudinal seal  142 , internal longitudinal seal  141 , and bottom seal  159 . A second transverse seal similar to the seal  145  may additionally be formed along the transverse edge  149 . The second transfer seal may be an alternative seal to seal  145 . In some embodiments, the container may include handles  50 , which may also be sealed together at  150 . These seals may be made after produce, or other content, has been placed in the container  50 . The seals may be made with mechanical attachment (e.g. zip style), with heat, with an adhesive, or any other way known in the art. The first wall and the second wall of the container  50  may be sealed along adhesive seals shown in  FIG. 12A . For example, seals on the first wall  50   a  may include one or more of  141   a ,  142   a ,  159   a ,  150   a  and  145   a . Seals on the second wall  50   b  may include one or more of  141   b ,  142   b ,  159   b ,  150   b  and  145   b . The seals may form the boundary around an unattached portion defining the interior  147  of the container  50 . The interior  147  may receive the produce or other content. Seals  141   a ,  142   a ,  159   a ,  150   a    145   a ,  141   b ,  142   b ,  159   b ,  150   b  and  145   b  are operable to connect walls which are made up of multiple plies of film. Thus these seals do not necessarily extend between plies  105 ,  107  but may do so. This seals may extend merely from plié  105  to ply  105  or ply  107  to ply  107 , thus forming walls of the containers. It should be noted that in situation in which an adhesive is used, it may be placed on each of the “a” and “b” locations, such as  141   a  and  141   b  for example. However it may be placed on only one of these locations such as  141   a  and when the structure  100  is folded  141   a  may align with  141   b  such that he seal is formed in both locations. This may apply to  142   a,b    159   a,b  and  145   a,b  as well. 
     The plies  105 ,  107  or similar structures may be heat-sealed together. Alternatively the plies  105 ,  107  may be adhesively sealed together with a UV curable adhesive. The UV curable adhesive may be applied to one or both plies  105 ,  107 , the plies may then be laid over top of one another and then sealed together by applying an ultraviolet light. In various embodiments, the adhesive may be printed onto one or both plies  105 ,  107  to form the various designs, patterns, or like that make up the internal structures such as the air chambers. The UV curable adhesively sealed plies  105 ,  107  may be folded over to form separate walls of container  50 . The separate walls may also have a UV curable adhesive printed thereon and then be sealed together with the UV light to form the container  50 . After forming the container  50 , the inflation chambers formed between plies  105 ,  107  may be inflated and sealed off via heat sealing to keep the chambers inflated. 
     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 lines of weakness  126  in the web  100  is disposed between a pair of adjacent chambers  120 . Preferably, each line of weakness  126  is disposed between two adjacent transverse seals  118  and between two adjacent chambers  120 , as depicted in  FIGS. 1A-D . The transverse lines of weakness  126  facilitate separation of adjacent inflatable cushions  120 . 
     The transverse lines of weakness  126  can include a variety of lines of weakness known by those of ordinary skill in the art. For example, in some embodiments, the transverse lines of weakness  126  include rows of perforations, in which a row of perforations includes alternating lands and slits spaced along the transverse extent of the row. The lands and slits can occur at regular or irregular intervals along the transverse extent of the row. Alternatively, for example, in some embodiments, the transverse lines of weakness  126  include score lines or the like formed in the web material. 
     The transverse lines of weakness  126  can be formed from a variety of techniques known to those of ordinary skill in the art. Such techniques include, but are not limited to, cutting (e.g., techniques that use a cutting or toothed element, such as a bar, blade, block, roller, wheel, or the like) and/or scoring (e.g., techniques that reduce the strength or thickness of material in the first and second plies, such as electromagnetic (e.g., laser) scoring and mechanical scoring). 
     In accordance with various embodiments, the inflatable flexible structure may be usable with variety of inflation and sealing devices. As an example, turning now to  FIG. 2 , an inflation and sealing device  101  for converting a flexible structure such as web  100  of uninflated material into a series of inflated pillows or cushions  120  is provided. As shown in  FIG. 2 , the uninflated web  100  can be a bulk quantity of supply, uninflated material. For example, the bulk quantity of uninflated material may be a roll of the material  134  as illustrated in  FIGS. 2 and 3 . The web  100  may be rolled around an inner support tube  133 . 
     The inflation and sealing device  101  may include a bulk material support  136 . The bulk quantity of uninflated material may be supported by the bulk material support  136 . For example, the bulk material support may be a tray operable to hold the uninflated material, which tray can be provided by a fixed surface or a plurality of rollers for example. To hold a roll of material the tray may be concave around the roll or the tray may convex with the roll suspended over the tray. The bulk material support may include multiple rollers which suspend the web. The bulk material support may include a single roller that accommodates the center of the roll of web material  134 . As illustrated in  FIGS. 2-4 , the roll of the material  134  may be suspended over the bulk material support  136 , such as a spindle passing through the core  133  of the roll of the material  134 . Typically, the roll core is made of cardboard or other suitable materials. The material support  136  may rotate about an axis Y. 
     The web  100  may be suspended over a guide  138  after being pulled off of the supply of uninflated material (e.g., roll  134 ). The guide may provide support to the web  100  upon a transition from the bulk quantity of uninflated material to the sealing and inflation mechanism  103 . The guide may be a stationary rod extending from a support member  141 . The guide  138  directs the web  100  away from the bulk quantity of uninflated material (e.g. roll  134 ) and steadily along a material path “B” along which the material is processed in a longitudinal direction “A”. As the bulk quantity of uninflated material may change position or dimension as the web  100  is continuously pulled from it (e.g. the roll  134  may decrease in diameter as material is pulled off), the guide may maintain alignment with the sealing and inflation mechanism despite these changes, and preferably with the upstream end of inflation tip  142 . The guide  138  can be configured to limit the material  134  from sagging between the inflation nozzle  140  and roll  134 , and can help maintain any desired tension in the web  100  of the material. 
       FIG. 4  illustrates a view of the inflation and sealing device  101  along axis Y. The material support  136  is shown on its end, and the length of the guide  138  is shown in an isometric view illustrating an angular difference between the two.  FIG. 5  illustrates a front view showing the end of guide  138  but a bottom isometric view of material support  136 . In accordance with embodiments discussed herein, the material support  136  and the guide  138  may rotate around axes Y and X respectively. The axis X may be perpendicular to the support member  141  with Y being non-perpendicular to the support member  141 . 
     In accordance with various embodiments, the web  100  may travel through the inflation and sealing device  101  along path E. As illustrated in  FIGS. 3 and 4 , the film path E extends along the nozzle  140 . An axis Z is located where the film path E follows the nozzle  140 . In accordance with various embodiments, the direction that nozzle  140  points is the same direction axis Y points. For example if nozzle  140  points up (e.g. away from base  183 ) then axis Y points up. If nozzle  140  points down (e.g. toward base  183 ) then axis Y points down. 
     In various embodiments, the web  100  may pass above the guide  138 . In such embodiments, the material support  136  and axis Y may be angled with respect to guide  138  such that the material support  136  and axis Y point in the same direction as the web  100  passes over guide  138 . If web  100  passes over guide  138  then the material support  136  may point up relative to the guide  138 . If web  100  passes under then guide  138 , then the material support  136  may point down relative to guide  138 . 
     In accordance with various embodiments, the web  100  passes through the inflation and sealing assembly  103  and extends away from the inflation and sealing device  101  in a transverse direction which is perpendicular to longitudinal direction A in which the web  100  exits the inflation and sealing device  101 . 
     When the web  100  is removed from the material support  136  and is positioned at an angle different from the guide  138 , the web  100  includes a slight twist as it is removed from the bulk quantity of uninflated material (e.g. roll  134 ) and re-aligned over and in contact with guide  138 . The web  100  may roll off of material support  136  tangentially and thereby forming a plane (or a surface that approximates a plane tangential with the surface of the roll  134 ) that is parallel with the axis of material support  136 . The web  100  may also engage guide  138  tangentially forming a different plane (or approximating a different plane tangent with the guide  138 ). The web may merely reflect tangential planes as if it maintained tangential contact with the material support  136  or guide  138  even if in practice there is tension on one transverse end of the web  100  and slack on the other transverse end of the web  100 . In order to accommodate both tangential contacts the web  100  may realign or twist slightly between the material support  136  and guide  138 . 
     In accordance with various embodiments, the nozzle  140  may inflate web  100  not only at a transverse edge but may engage an inflation channel located at any transverse distance between the longitudinal edges; i.e., the inflation and sealing device  101  fills a central channel with chambers on both transverse sides of the inflation channel. The web  100  may roll off of material support  136  and over guide  138  in a manner that aligns such a central inflation channel with the nozzle  140 . 
     In various embodiments the material support  136  may include a spindle  200 . The spindle  200  may be axially aligned along axis Y with a motor  220 . The motor  220  and the spindle  200  may be attached via a bulkhead connector  222 . The bulk head connector  222  may have a mounting surface  223 . The mounting surface may attach to the backside of the support member  141  such that the motor  220  may be positioned on one side and the spindle  200  may be positioned on the other side as illustrated in  FIG. 6 . The mounting surface  223  may form an angle with axis Y such that axis Y is not perpendicular thereto. For example,  FIG. 6  shows mounting surface  223  as parallel with vertical plate  184 . As such, λ represents the angle between mounting surface  223  and Y. Instead, the mounting surface  223  may be angled such that as it attaches to the back side of the support member  141 , it tilts the spindle  200  and motor  220  relative to the support member  141 . An example of this structure is shown in  FIG. 6  with the angle λ which may also represent the angle between mounting surface  223  and the axis Y. Spindle  200  may be supported within the bulk head connector  222  by bearings  214  and  224 . The bearings  214 , 224  may allow the spindle  200  to be rotatable independent of the bulkhead connector  222  and ultimately the support member  141 , to which the bulkhead connector  222  attaches. In various embodiments, the spindle may be supported on a shaft, surface bearings, or by the motor directly. The spindle  200  may be locked into place on the bulk head  222  with clip  226 . Cover  228  and bulk head connector  222  may form an enclosure around motor  220 . 
     The spindle  200  may include two sections, a body portion  202  and a tip portion  204 . The body portion  202  and the tip portion  204  may be formed of different materials.  6 . The spindle  200  preferably has core support portions  206 , which are outwardly facing surfaces spaced circumferentially about axis Y from each other to provide radially recessed areas  208  therebetween. The core support portions  206  protrude radially from the axis Y higher than the surfaces of the spindle  200  in the radially recessed areas  208 . The core support portions can collectively define and be positioned along a phantom cylindrical surface that will correspond closely to the interior, hollow, surface within a supply roll  134 . If other shaped cores are to be used, the core support portions can be arranged in other shapes. The core support portions  206  can be curved circumferentially along this phantom cylindrical surface or can be flat or have other shapes. The recessed areas  208  are positioned radially inward of the phantom cylinder, so that they entirely or in large part do not contact the interior of a supply roll mounted on the spindle  200 . The recessed areas  208  have substantially flat surfaces in the embodiment shown, but other configurations can be used. 
     In the embodiment of  FIG. 7 , the recessed areas  208  lie below the phantom cylinder  207 , and the core support portions  206  generally follow the phantom cylinder  207 , although other shapes can be used. In this manner, the spindle  200  may be generally triangular in shape having three core support portions  206 , but can alternatively have four, five, or more core support surfaces, and the core support portions can be evenly or unevenly distributed circumferentially about the spindle. In one example, as shown in  FIG. 8  viewed down the Y axis, the spindle  200  may have an axial cross section that forms a triangle. The core support surfaces  206  preferably extend substantially axially with respect to the spindle (transversely with respect to the material path or machine direction in the embodiment of  FIG. 2 ) to help in sliding a web roll core  133  on and off the spindle. 
     By providing the recessed areas between the core support portions  206  provides the spindle with a discontinuous support surface in which the contact area it has with a core  133  of a supply web roll  134  can be reduced compared to traditional, continuous-surface cylindrical spindles. This reduces the friction between the spindle  200  and core  133 , allowing the core  133  to be more easily inserted and slid off from the spindle  200 . Additionally, as is common and can be seen in  FIG. 4 , the core  133  can be deformed, such as by damage during shipping of the supply material roll  134 . Damaged, out-of-round cores can be very difficult or impossible to insert onto a fully cylindrical spindle. The recessed areas  208  on the discontinuous spindle surface can accommodate deformations of the core  133  that extend inwardly between the core support portions  206 , allowing dented or flattened cores to remain useable. In this way, the core support surfaces  206   a,b,c  or a plurality of grip elements  210  which extend from the core support surfaces  206   a,b,c , may contacts or occupy only a fraction of the outer core surface circumference. The plurality of contacts may contact a finite number of points within an internal surface of a hollow tube onto which the web of material is rolled. In various examples, the plurality of grip elements  210  may extend beyond the generally cylindrical shape shown by line  207 . The plurality of contacts may form a larger diameter around the spindle than the size of the inner diameter of inner support tube  133 . This structure would allow the plurality of contacts to engage in an interference fit with the core  133  while the minimized outer cylindrical surface segments  206   a,b,c  minimize other contact within the core  133 . Preferably, the grip elements  210  are biased outwardly and are resiliently movable inwardly into the spindle  200 . Such bias can be provided by springs within the spindle. The outer surface of the grip elements  210  can be spherical, conical, or have another shape that preferably facilitates sliding of the core  133  during loading and unloading on or from the spindle, and that grips the inner surface of the core  133  during use, to help transfer torque from the spindle to the roll, and preferably from the brake  137 , described below. A chamfer  204  at the end of tip portion  204  may additionally reduce the effort of inserting spindle  200  into the inner support tube  133 . 
     Referring back to  FIGS. 2-6 , the support element  136  may be connected with a brake  137 . The brake  137  may prevent or inhibit bunching up of the web material  100  and maintain a desired tension in the web material  100  as it is unwound from the roll  134  and as it is fed onto and/or into the inflation and sealing mechanism. The brake  137  may prevent or inhibit release of the bulk uninflated material from the support  136 . For example, the brake  137  may inhibit the free unwinding of the roll  134 . The brake may also assure that the roll  134  is unwound at a steady and controlled rate. The brake  137  may be provided by any mechanism that provides control. For example, according to one embodiment, a spring-loaded leather strap or other friction mechanism can be used as a drag brake on the bulk material support  136 . In another embodiment, the brake  134  may be an electric motor or other actuator used to provide resistance to the rotation of the bulk material support  136  as the roll  134  is unwound. As shown in  FIGS. 7-8 , the support element  136  is spindle  200  which is axially connected to a brake which may operate as a resistance mechanism. The resistance mechanism resists rotation of the support element  136  (e.g. spindle  200 ). The resistance mechanism may be motor  220  which controls rotation of the spindle  200 , thereby controlling advancement of the web  100  by either positively driving rotation of spindle  200  or retarding the rotation of spindle  200 . By retarding the rotation of spindle  200 , the brake can also increase tension on the twisted web proximal to the support member  141 , maintaining proper alignment with the inflating/sealing mechanism. 
     Preferably, the inflation and sealing device  101  is configured for continuous inflation of the web  100  as it is unraveled from the roll  134 . The roll  134 , preferably, comprises a plurality of chain of chambers  120  that are arranged in series. To begin manufacturing the inflated pillows from the web material  100 , the inflation opening  116  of the web  100  is inserted around an inflation assembly, such as an inflation nozzle  140 . In the embodiment shown in  FIG. 2 , preferably, the web  100  is advanced over the inflation nozzle  140  with the chambers  120  extending transversely with respect to the inflation nozzle  140  and outlet  146 . The outlet  146 , which can be disposed on a radial side and/or the upstream tip of the nozzle  140 , for example, directs fluid from nozzle body  144  into the chambers  120  to inflate the chambers  120  as the web  100  advances along the material path “E” in a longitudinal direction “A”. The inflated web  100  is then sealed by a sealing drum  166  in the sealing area  174  to form a chain of inflated pillows or cushions. 
     The side inflation area  168  in the embodiment of  FIG. 3  is shown as the portion of the inflation and sealing device  101  along the path “E” adjacent the side outlets  146  in which air from the side outlets  146  can inflate the chambers  120 . In some embodiments, the inflation area  168  is the area disposed between the inflation tip  142  and entry pinch area  176 , described below. The web  100  is inserted around the inflation nozzle  140  at the inflation tip  142 , which may be disposed at the forward-most end of the inflation nozzle  140 . The inflation nozzle  140  inserts fluid, such as pressured air, along fluid path B into the uninflated web material through nozzle outlets, inflating the material into inflated pillows or cushions  120 . The inflation nozzle  140  can include a nozzle inflation channel that fluidly connects a fluid source with the nozzle outlets. It is appreciated that in other configurations, the fluid can be other suitable pressured gas, foam, or liquid.  FIGS. 3, 9, 10, and 11  illustrates a various view of the inflation and sealing device  101 . As discussed in various embodiments, the fluid source can be disposed behind the support member  141  having a horizontal plate  183  and vertical plate  184  or other structural support for the nozzle and sealing assemblies, and preferably behind the inflation nozzle  140 . The fluid source is connected to and feeds the fluid inflation nozzle conduit  143 . The web  100  is fed over the inflation nozzle  140 , which directs the web to the inflation and sealing assembly  103 . The web  100  is advanced or driven through the inflation and sealing device  101  by a drive mechanism, such as by a driver or sealing drum  166  or the drive roller  160 , in a downstream direction along a material path “E”. 
     In accordance with various embodiments, the nozzle, blower sealing assembly, and drive mechanisms, and their various components or related systems may be structured, positioned, and operated as disclosed in any of the various embodiments described in the incorporated references such as for example U.S. patent application Ser. No. 13/844,741. Each of these embodiments may be incorporated to the inflation and sealing device  101  as discussed herein. 
     After being fed through the web feed area  164 , the first and second plies  105 , 107  are sealed together by the sealing assembly and exit the sealing drum  166 . The sealing drum  166  includes heating elements, such as thermocouples, which melt, fuse, join, bind, or unite together the two plies  105 , 107 , or other types of welding or sealing elements. The web  100  is continuously advanced through the sealing assembly along the material path “E” and past the sealing drum  166  at a sealing area  174  to form a continuous longitudinal seal  170  along the web by sealing the first and second web plies  105 , 107  together, and exits the sealing area at an exit pinch area  178 . The exit pinch area  178  is the area disposed downstream the entry pinch area  164  between the belt  162  and the sealing drum  166 , as shown in  FIG. 4 . The sealing area  174  is the area between the entry pinch area  164  and exit pinch area  178  in which the web  100  is being sealed by the sealing drum  166 . The longitudinal seal  170  is shown as the phantom line in  FIGS. 1A-D . Preferably, the longitudinal seal  170  is disposed a transverse distance from the first longitudinal edge  102 , 106 , and, most preferably, the longitudinal seal  170  is disposed along the mouths  125  of each of the chambers  120 . 
     As shown in  FIG. 4 , the sealing drum  166  may be arranged above the belt  162 . The drive roller  160  may be positioned downstream the feed roller  158  and tension roller  156  with the sealing drum  166  there between. The sealing drum  166  may be disposed such that a portion of the sealing drum  166  vertically overlaps the feed roller  158 , tension roller  156 , and drive roller  160  so that the belt  162  is deformed at the sealing area  174  to have a generally U-configuration. Such configuration increases the tension of the belt  162  at the sealing area  174 , and facilitates the pinching of the web  100  between the sealing drum  166  and the belt  162  at the sealing area  174 . The inflation and sealing assembly  103  configuration described also reduces the amount of contact of the web  100  during sealing, which reduces bending of the inflated web. As shown in  FIG. 7 , the contact area is the sealing area  174  between the entering pinch area  164  and exiting pinch area  174 . 
     In the embodiment shown, the web  100  enters the sealing assembly at the entry pinch area  176  at an angle sloping downward with respect to the horizontal. Additionally, the web  100  exits the sealing area  174  at an angle sloping upward with the respect to the horizontal so that the web  100  is exiting facing upwards toward the user. By having the intake and outtake sloped as described herein, the inflation and sealing device  101  allows for easy loading and extracting of the web as well as easy access to the web. Thus, the inflation and sealing device  101  can be positioned below eye level, such as on a table top, without the need of a high stand. The sloping downward intake and sloping upward outtake of the web  100  from the sealing assembly provides for the material path “E” to be bent at an angle α between the entry pinch area  176  and the exit pinch area  174  (the entry pinch area  176  and exit pinch area  174  are further described below). The angle α between the entry pinch area  176  and exit pinch area  174  is, for example, at least about 40 degrees up to at most about 180 degrees. The angle α may be about 90 degrees. Other entry and exit angles can be employed as known in the art in alternative embodiments. 
     In accordance with various embodiments, the sealing assembly may be protected by a removable cover. Likewise, the belt mechanism, e.g. belt  162 , tension roller  156 , and feed roller  158  may also include a removable cover  173 . This allows for a user to easily remove the web or clear up or fix jams within the machine. 
     In accordance with various embodiments, one or more of the elements of inflation and sealing device  101  may drive web  100  through the system. For example, the sealing drum  166  may be connected to a motor which rotates it in a direction “F”. As described in various embodiments (see e.g. application Ser. No. 13/844,741), other elements may also drive the system, such as roller  160 . In other embodiments discussed in the incorporated references, roller  160  is indicated as a drive roller; however, it may be noted that roller  160  may be either an idler roller or an active drive roller. For example, roller  160  may be connected to the same motor or the same drive mechanism associated with the sealer drum  166  that causes the drum to rotate. In other configurations, the sealing drum  166  may be passive (e.g. an idler) or actively driven by a motor. In one example, the sealing drum  166  may be passive and merely be rotated in response to the advancing web  100  or belt  162 . 
     In accordance with various embodiments, the inflation and sealing device can have more than one belt. For example one belt may drive the various rollers and a second belt may pinch the web against the sealing drum. In various embodiments, the inflation and sealing device may have no belts. For example the sealing drum may pinch the web against a stationary platform and drive the web thorough the inflation and sealing device at the same time. Additional description and embodiments of such structures may be disclosed in U.S. Pat. Nos. 8,061,110 and 8,128,770 and Publication No. 2011/0172072 each of which is herein incorporated by reference. 
     Although some embodiments do not have a post-seal control element, the inflation and sealing assembly  103  shown in  FIG. 2  includes a plurality of post-seal control elements. In various embodiments, the post-seal control element may be a movable or stationary surface, a roller, or any device that can contact the belt  162  or the web  100 . For example, a post-seal control element can include roller  160  as discussed above. The roller  160  supports the web  100  exiting from the inflation and sealing assembly  103  and may be operable to guide the belt. As illustrated in  FIGS. 9-11 , the roller  172  may also be a post-seal control element. In various embodiments, there may be a single post-seal control element such as roller  160  as depicted in embodiments disclosed in the incorporated references (see e.g. Ser. No. 13/844,741). In other embodiments, there may be multiple post-seal control elements as illustrated in  FIGS. 9-11 . For example, a first post-seal control element (e.g. roller  172 ) can be disposed directly above a second post-seal control element (e.g. roller  160 ). 
     The two post-seal control elements (e.g. two rollers  160 , 172 ) pinch or press the web  100  so that the belt  162  abuts one or both of the surfaces of the elements. As the rollers  160 , 173  are disposed immediately downstream of the heating drum (or other heating mechanism in other embodiments), they provide a cooling region  179  disposed between two rollers  160 , 172 . Roller  160  in this embodiment acts as a principle cooling roller, since the sealed and cooling film is drawn around this roller  160 . Pinch roller  172  maintains the web in contact with the principle cooling roller  160  to help maintain the pressure between the two film plies as the seal cools to support the seal and surrounding area mechanically. In embodiments, such as the one shown, in which the belt  162  extends around roller  160 , the outer surface of this roller remain substantially stationary with respect to the web  100 , further helping support the seal in it&#39;s delicate state before it has cooled sufficiently. Roller  160  is typically made of a hard and tough material, such as steel or aluminum, to withstand the pressures and heat from the belt  162 , although a plastic or other material could be used in some embodiments. 
     In various embodiments, the post-seal control element such as roller  172  may have a larger-diameter area  171  opposing the belt than in adjacent parts of pinch roller  172 . This annular ridge  171  allows contact against the web  100 , while an adjacent smaller-diameter portion of roller  172  can remain out of contact therewith to help prevent sticking to the hot web. The roller  172  may be biased against the belt  162 , web  100 , and roller  160  by a spring-loaded tensioner  169 . The tension provided by the tensioner  169  may further hold the seal closed by the post-seal control element, and can allow the pinch roller  172  to be lifted off the web when needed. 
     To prevent or reduce sticking of the hot web  100  to the pinch roller  172 , the pinch roller is preferably made of, or has a surface of, a non-stick or low adhesion material such as polytetrafluoroethylene (PTFE) or other suitable material as discussed below. In accordance with various embodiments, the post-seal control element such as roller  160  may include a recessed annular surface  163 . The recessed annular surface  163  may receive the belt  162 . 
     When the web exits pinch area  178  between rollers  160  and  172  (these two rollers  160 ,  172  are at the exit of the sealing mechanism, such as the downstream exit from the device) there is a possibility that the hot film will stick to one of these rollers instead of cleanly exiting the device. In various embodiments, an element can be provided to help separate the film from the post-seal control elements. For example, roller  172  can have an annular ridge  161  extending proud the belt  162  or outer surface  167  of the roller  160  that supports the belt  162  against the web  100 , or that contacts the web  100 . This ridge  161  can be annular or have another suitable shape and can run around the roller to contact the web  100 , preferably transversely adjacent the longitudinal seal on the inflated web  100 , such as against the transverse end of the inflated chambers  120  adjacent the longitudinal seal  112 . At the pinch area  178 , the annular ridge  161  contacts the web  100 , typically against a transverse side of the inflated chambers  120  where due to the inflated shape, the chambers  120  have a degree of rigidity compared to the uninflated film. The elevated ridge provides a bump-off element that forcing the web  100  to deflect off the roller  160 . The annular ridge  161  is a second surface that causes the web to bend. The bend may cause a portion of the web  100 , located in the lateral direction relative to a first portion of the web  100  that is pressed between the first post-seal control element (e.g. roller  172 ) and the second post-seal control element (e.g. roller  160 ), to not stay in the same plane as the first portion of the web. Forcing different portions of web  100  into different planes may cause the web  100  to unseat, and often unstick, from the belt and/or the roller  160 . As such, the annular ridge  161  aids in automatically peeling the web  100  off the post-seal control elements. While described with respect to a roller, alternative embodiments can have a stationary ridge provided adjacent the roller  160  to guide the web off the cylinder. 
     As the heated web  100  may have a tendency to stick to the post-seal control elements, non-stick materials may mitigate this issue. For example, one or both post-seal control elements may be made from of coated with polytetrafluoroethylene (PTFE), anodized aluminum, ceramic, silicone, or like non-stick/low-adhesion materials. 
     In the embodiments shown, the inflation and sealing device  101  further includes a cutting assembly  186  to cut the web off the inflation nozzle when an inflation channel that receives and is closed around a longitudinal inflation nozzle  140  is used. As with other system components discussed herein, the cutting assembly may also be structured, provided, or included in accordance with the various embodiments described by the incorporated references discussed above. 
     While the inflatable packaging product  100  may be formed using the disclosed inflation and sealing device  101 , the inflation and sealing device is exemplary, and it should be well understood that other devices can be used to form the inflatable packaging product  100 , instead of or in addition to the sealing device  101 . 
     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. The content of U.S. patent application Ser. No. 13/844,741 is hereby incorporated by reference in its entirety. While useful features of the disclosure are discussed above, it will be appreciated that such features can be provided in ornamental arrangements on a web material. 
     While illustrative embodiments of the invention are disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the features for the various embodiments can be used in other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention.