Patent Publication Number: US-2022212433-A1

Title: Inflation nozzles for closed channel web materials

Description:
BACKGROUND 
     The present disclosure is in the technical field of inflation nozzles for closed channel web materials. More particularly, the present disclosure is directed to nozzle assemblies that includes blade carriers that can be coupled to and removed from manifold blocks in a toolless manner. 
     Consumers frequently purchase goods from mail-order or internet retailers, which package and ship the goods to the purchasing consumer via a postal service or other carrier. Millions of such packages are shipped each day. These items are normally packaged in small containers, such as boxes or envelopes. To protect the items during shipment, they are typically packaged with some form of protective dunnage that may be wrapped around the item or stuffed into the container to prevent movement of the item and to protect it from shock. 
     Common types of mailing envelope are sometimes referred to as “mailers.” In some cases, these mailers have cushioning to provide some level of protection for the objects transported therein. The outer walls of cushioned mailers are typically formed from protective materials, such as Kraft paper, cardstock, polyethylene-coated paper, other paper-based materials, polyethylene film, or other resilient materials. The inner walls of cushioned mailers are lined with cushioning materials, such as air cellular material (e.g., BUBBLE WRAP™ air cellular material sold by Sealed Air Corporation), foam sheets, or any other cushioning material. The outer walls are typically adhered (e.g., laminated) to the cushioning material when forming the mailers. 
     When goods are shipped in rigid containers, such as corrugated cardboard boxes, dunnage material is typically added to the containers to take up some of the void space within the containers. Inflated cushions, pillows, or other inflated containers are common void fill materials that are either placed loose in a container with an object or wrapped around an object that is then placed in a container. The cushions protect the packaged item by absorbing impacts that may otherwise be fully transmitted to the packaged item during transit, and also restrict movement of the packaged item within the carton to further reduce the likelihood of damage to the item. Another common form of void fill material is paper, such as Kraft paper, that has been folded or crumped into a low-density, three-dimensional pad or wad that is capable of filling void space without adding significant weight to the container. 
     It would be advantageous to automate the packaging process to minimize the amount of time required to package objects properly. However, given the wide variety of ways which objects can be packaged for shipping, automation of the packaging process can be challenging. 
     SUMMARY 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     In a first embodiment, a system includes a manifold block, a nozzle, and a blade carrier. The manifold block includes a gas inlet and a gas outlet. The gas outlet is in fluid communication with the gas inlet. The nozzle is configured to be coupled to the gas outlet of the manifold block, the nozzle including a conduit and a slot in the conduit. The blade carrier includes a body, a guard coupled to the body, and a blade coupled to the guard. The blade carrier is couplable to the manifold block so that so that a gap exists between the conduit and the guard. The wherein the blade is coupled to the blade carrier such that, when the blade carrier is couple to the manifold block, the blade is located in the gap between the conduit and the guard and a portion of the blade is located in the slot. 
     In a second embodiment, the guard of the blade carrier of the first embodiment is configured to be aligned with the slot when the blade carrier is coupled to the manifold block. 
     In a third embodiment, the nozzle of any of the previous embodiments further includes a wear cap configured to close an end of the conduit. 
     In a fourth embodiment, the blade of the previous embodiments is arranged so that, when the blade carrier is coupled to the manifold block, the blade extends farther forward along the conduit than the blade extends forward along the guard. 
     In a fifth embodiment, the blade carrier of the previous embodiments is removably couplable to the manifold block. 
     In a sixth embodiment, the blade carrier of the previous embodiments is configured to be coupled to a nozzle portion of the manifold block. 
     In a seventh embodiment, a system includes a manifold block, a nozzle, and a blade carrier. The manifold block comprising a gas inlet and a gas outlet. The gas outlet is in fluid communication with the gas inlet. The nozzle configured to be coupled to the gas outlet of the manifold block. The blade carrier includes a body having a bore therein, a guard coupled to the body so that a gap exists between a portion of the body and a portion of the guard, and a blade located in the gap between the portion of the body and the portion of the guard. The blade carrier is configured to be coupled to the manifold block in a toolless manner by sliding a portion of the nozzle through at least a portion of the bore until the blade carrier is in contact with the manifold block. 
     In an eighth embodiment, the manifold block of the seventh embodiment includes a slot and wherein the guard of the blade carrier is configured to be aligned with the slot when the blade carrier is coupled to the manifold block. 
     In a ninth embodiment, the manifold block of the eighth embodiment further includes side walls on either side of the slot. The side walls are configured to deter rotation of the blade carrier. 
     In a tenth embodiment, the manifold block of any of the eight to ninth embodiments further includes a ball detent in the slot. 
     In an eleventh embodiment, the guard of the tenth embodiment includes a ball detent depression configured to engage the ball detent in the slot. When the ball detent is engaged with the ball detent depression, the ball detent depression deters the blade carrier from moving away from the manifold block. 
     In a twelfth embodiment, the nozzle of any of the seventh to eleventh embodiments includes a conduit configured to be coupled to the gas outlet of the manifold block. 
     In a thirteenth embodiment, the system of the twelfth embodiment is configured such that, when the blade carrier is coupled to the manifold block, an end of the conduit extends beyond an end of the body of the blade carrier. The end of the conduit that extends beyond the end of the body of the blade carrier includes a wear cap. The manifold block and the nozzle are configured such that gas can be inserted into the gas inlet of the manifold block, pass through the manifold block, pass out of the manifold block and into the conduit through the gas outlet, and then pass out of the conduit through the wear cap. 
     In a fourteenth embodiment, the system of any one of the twelfth to thirteenth embodiments is configured such that, when the blade carrier is coupled to the manifold block, the conduit remains inside of the bore. The body of the blade carrier includes an outlet. The manifold block, the nozzle, and the blade carrier are configured such that gas can be inserted into the gas inlet of the manifold block, pass through the manifold block, pass out of the manifold block and into the conduit through the gas outlet, pass out of the conduit into the bore, and then pass out of the body of the blade carrier through the outlet. 
     In a fifteenth embodiment, the body of the blade carrier of the fourteenth embodiment includes a wear cap. When the blade carrier is coupled to the manifold block, the wear cap is on an end of the body that is furthest from the manifold block. 
     In a sixteenth embodiment, the system of any of the seventh to fifteenth embodiments is configured such that the body includes a first slot, the guard includes a second slot, and a bottom of the blade is configured to slide in the first slot and a top of the blade is configured to slide in the second slot. 
     In a twentieth embodiment, the blade carrier of the sixteenth embodiment includes a set screw configured to hold the blade in place with respect to the body and the guard. 
     In an eighteenth embodiment, the blade of any of the sixteenth and seventeenth embodiments is arranged so that the blade extends farther forward along the body than the blade extends forward along the guard. 
     In a nineteenth embodiment, the gas inlet of any of the seventh to eighteenth embodiments is configured to be coupled to a connector and wherein the connector is configured to be coupled to a gas source. 
     In a twentieth embodiment, the manifold block of any of the seventh to nineteenth embodiments includes a mounting portion and a nozzle portion. The gas inlet is in the mounting portion. The gas outlet is in the nozzle portion. 
     In a twenty first embodiment, the nozzle portion of the twentieth embodiment is narrower than the mounting portion. 
     In a twenty second embodiment, a width of the nozzle portion of any of the twentieth to twenty first embodiments is similar to a width of the body. 
     In a twenty third embodiment, a method includes mounting a manifold block to a support structure, coupling a gas inlet of the manifold block to a gas source, and coupling a nozzle to a gas outlet of the manifold block. The gas inlet is in fluid communication with the gas outlet. The method further includes coupling, in a toolless manner, a blade carrier to the manifold block by sliding a portion of the nozzle through at least a portion of a bore of the blade carrier until the blade carrier is in contact with the manifold block. The bore of the blade carrier is in a body of the blade carrier. The blade carrier further includes a guard coupled to the body so that a gap exists between a portion of the body and a portion of the guard. The blade carrier further includes a blade located in the gap between the portion of the body and the portion of the guard. 
     In a twenty fourth embodiment, the manifold block of the twenty third embodiment includes a slot and the coupling of the blade carrier to the manifold block further includes aligning the guard with the slot. 
     In a twenty fifth embodiment, the blade carrier of any of the twenty third to twenty fourth embodiments is in contact with the manifold block when a ball detent of the manifold block is engaged with a ball detent depression in the blade carrier. 
     In a twenty sixth embodiment, a web material of any of the twenty third to twenty fifth embodiments includes a closed channel in fluid communication with a plurality of chambers. The method further includes feeding the web material past the manifold block so that the closed channel passes around the body of the blade carrier and the closed channel is cut by the blade. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein: 
         FIGS. 1A and 1B  depict perspective and exploded perspective views, respectively, of an embodiment of a nozzle assembly for use with closed channel web materials, in accordance with the embodiments disclosed herein; 
         FIGS. 2A and 2B  depict top and bottom perspective views, respectively, of a manifold block from the nozzle assembly shown in  FIGS. 1A and 1B , in accordance with the embodiments disclosed herein; 
         FIG. 3  depicts a perspective view of a nozzle from the nozzle assembly shown in  FIGS. 1A and 1B , in accordance with the embodiments disclosed herein; 
         FIG. 4  depicts a perspective view of a blade carrier from the nozzle assembly shown in  FIGS. 1A and 1B , in accordance with the embodiments disclosed herein; 
         FIG. 5  depicts an example of the nozzle assembly shown in  FIGS. 1A and 1B  being used to inflate and cut an inflatable web material, in accordance with the embodiments disclosed herein; 
         FIGS. 6A and 6B  depict perspective and exploded perspective views, respectively, of another embodiment of a nozzle assembly for use with closed channel web materials, in accordance with the embodiments disclosed herein; 
         FIGS. 7A and 7B  depict top and bottom perspective views, respectively, of a manifold block from the nozzle assembly shown in  FIGS. 6A and 6B , in accordance with the embodiments disclosed herein; 
         FIG. 8  depicts a perspective view of a nozzle from the nozzle assembly shown in  FIGS. 6A and 6B , in accordance with the embodiments disclosed herein; 
         FIGS. 9A, 9B, and 9C  depict various perspective views of a blade carrier from the nozzle assembly shown in  FIGS. 6A and 6B , in accordance with the embodiments disclosed herein; and 
         FIG. 10  depicts an example of the nozzle assembly shown in  FIGS. 6A and 6B  being used to inflate and cut an inflatable web material, in accordance with the embodiments disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes embodiments of nozzle assemblies that can be used to inflate closed channel web materials. In some embodiments, the nozzle assembly includes a manifold block, a nozzle, and a blade carrier. The manifold block includes a gas inlet and a gas outlet. The gas outlet is in fluid communication with the gas inlet. The nozzle is configured to be coupled to the gas outlet of the manifold block. The blade carrier includes a body having a bore therein, a guard coupled to the body so that a gap exists between a portion of the body and a portion of the guard, and a blade located in the gap between the portion of the body and the portion of the guard. The blade carrier is configured to be coupled to the manifold block in a toolless manner by sliding a portion of the nozzle through at least a portion of the bore until the blade carrier is in contact with the manifold block. By being couplable and removable in a toolless manner, the blade carrier and the blade are easily replaceable when the blade and/or any other wearable part needs to be replaced. 
     Web materials can be formed into a pouch for packaging an object. In some embodiments, web materials are inflatable air cellular material. As used herein, the term “air cellular material” herein refers to bubble cushioning material, such as BUBBLE WRAP® air cushioning material sold by Sealed Air Corporation, where a first film or laminate is formed (e.g., thermoformed, embossed, calendared, or otherwise processed) to define a plurality of cavities and a second film or laminate is adhered to the first film or laminate in order to close the cavities. Examples of air cellular materials are shown in U.S. Pat. Nos. 3,142,599, 3,208,898, 3,285,793, 3,508,992, 3,586,565, 3,616,155, 3,660,189, 4,181,548, 4,184,904, 4,415,398, 4,576,669, 4,579,516, 6,800,162, 6,982,113, 7,018,495, 7,165,375, 7,220,476, 7,223,461, 7,429,304, 7,721,781, and 7,950,433, and U.S. Published Patent Application Nos. 2014/0314978 and 2015/0075114, the disclosures of which are hereby incorporated by reference in their entirety. 
     As used herein, an “object” may comprise a single item for packaging or grouping of several distinct items where the grouping is to be in a single package. Further, an object may include an accompanying informational item, such as a packing slip, tracking code, a manifest, an invoice, or printed sheet comprising machine-readable information (e.g., a bar code) for sensing by an object reader (e.g., a bar code scanner). In some embodiments, each of the objects includes an object identifier. In some examples, the object identifier includes one or more of a barcode, a quick response (QR) code, a radio frequency identification (RFID) tag, any other form a machine-readable information, human-readable information, or any combination thereof. 
     In some embodiments, a web material includes two longitudinal edges. Between the longitudinal edges are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers. When initially formed, the chambers are in an uninflated state and the chambers are capable of being inflated. In some embodiments, each of the chambers extends substantially transversely across the web material and the pattern of the chambers generally repeats in the longitudinal direction. 
     In some embodiment, each of the chambers includes a port that is open and a distal end that is closed. The ports can be located proximate one of the two longitudinal edges and the distal ends located proximate the other of the two longitudinal edges so that the ports extend substantially transversely across the web material. The juxtaposed sheets are sealed between the ports and the distal ends such that each of the chambers has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers are capable of being inflated by inserting a gas (e.g., air) through the ports. Once the chambers are inflated, the cells form three-dimensional shapes (sometimes referred to as “bubbles”) along the inflated chambers. In some embodiments, a pair of adjacent chambers are offset so that the cells of one of the chambers are aligned with the interconnecting channels of a subsequent one of the chambers. 
     To aid in inflation of the chambers, the web material can include a common channel that is in fluid communication with each of the chambers. In some embodiments, a nozzle can be inserted in the common channel and direct a gas into the common channel. The gas inserted into the common channel can pass through the ports to inflate the chambers. Coupled to the nozzle may be a sealing device configured to close the ports after inflation of the chambers. Examples of web materials with common channels are described in U.S. Patent Application No. 62/783,250, and in U.S. Patent Application No. 62/845,354, the contents of each of which are hereby incorporated by reference in their entirety. 
     In some embodiments, the common channel of an inflatable web material can be an “open” channel where the two sheets are not connected to each other. An open channel allows a nozzle to be located in the common channel while the two sheets of the channel are able to pass on either side of the nozzle without cutting the channel. In other embodiments, the common channel of an inflatable web material can be a “closed” channel where the two sheets are connected to each other. A nozzle can be inserted into the closed channel. The closed channel may improve inflatability of the chambers because the possibility of the gas to exit a closed channel is significantly lower than with an open channel. However, a closed channel requires the two sheets to be cut before the sheets can pass on either side of the nozzle. 
     Depicted in  FIGS. 1A and 1B  are perspective and exploded perspective views, respectively, of an embodiment of a nozzle assembly  100  for use with closed channel web materials. The nozzle assembly  100  includes a manifold block  110 , a nozzle  130 , and a blade carrier  140 .  FIGS. 2A and 2B  depict more detailed top and bottom perspective views, respectively, of the manifold block  110 .  FIG. 3  depicts a more detailed perspective view of the nozzle  130 .  FIG. 4  depicts a more detailed perspective view of the blade carrier  140 . 
     The nozzle assembly  100  is configured to convey gas from a gas source  102  into a closed channel of an inflatable web material and to cut open the closed channel of the inflatable web material. In the depicted embodiment, the gas source  102  is a gas line that can be coupled to a compressor, a pressure gas container (e.g., a cylinder), and the like. Also depicted in  FIGS. 1A and 1B  is a connector  104  configured to couple the gas source  102  to the manifold block  110 . In other embodiments, the gas source  102  may be connected directly to the manifold block  110  and/or coupled to the manifold block  110  via a different type of connector. 
     The manifold block  110  includes a mounting portion  112 . The mounting portion  112  of the manifold block  110  includes a gas inlet  114 . In some embodiments, the gas inlet  114  is a threaded bore into which a threaded end of the connector  104  can be coupled. In the depicted embodiment, the mounting portion  112  of the manifold block  110  includes mounting holes  116 . In some embodiments, a fastener (e.g., a bolt, a machine screw, etc.) can be inserted through each of the mounting holes  116  to mount the manifold block  110  to a structure, such as a support structure of an automated packaging station. 
     The manifold block  110  also includes a nozzle portion  118 . The nozzle portion  118  of the manifold block  110  includes a gas outlet  120 . The gas outlet  120  is in fluid communication with the gas inlet  114  so that gas that passes into the gas inlet  114  passes to the gas outlet  120 . In the depicted embodiment, the nozzle portion  118  includes a slot  122 . The slot  122  is positioned on a down-ward facing surface of the manifold block  110 . The slot  122  has side walls  124 . In some embodiments, the slot  122  is linear and extends substantially parallel to and aligned with an axis of the gas outlet  120 . The manifold block  110  also includes a ball detent  126 . In the depicted embodiment, the ball detent  126  is positioned in the slot  122 . 
     The nozzle assembly  100  includes a nozzle  130 . The nozzle  130  includes a conduit  132  that has a passageway  134  for passage of gas. The conduit  132  is configured to be coupled to the gas outlet  120  of the manifold block  110 . In some embodiments, the conduit  132  is an aluminum tube that can be pressed into the gas outlet  120  to couple the nozzle  130  to the manifold block  110 . In some embodiment, an end of the conduit  132  includes external threads that can be threaded into internal threads of the gas outlet  120  to couple the nozzle  130  to the manifold block  110 . 
     In the depicted embodiment, the nozzle  130  includes a wear cap  136  that forms an outlet  138 . In the depicted embodiment, the wear cap  136  is couplable to an end of the conduit  132  that is opposite of the end of the conduit  132  that is coupled to the gas outlet  120 . The wear cap  136  may contact a web material that is fed past the nozzle assembly  100 , resulting in greater wear on the wear cap  136  than on other parts of the nozzle  130 , such as the conduit  132 . In some embodiments, the conduit  132  is made from a material (e.g., a metal, such as aluminum) that is more durable than a material (e.g., plastic) of the wear cap  136 . In this way, the wear cap  136  may be a “wear part” that is intended to be replaced periodically but has a relatively low cost compared to the conduit  132 . 
     The blade carrier  140  includes a body  142  that has a bore  144 . In the depicted embodiment, the body  142  and the bore  144  are dimensioned so that the blade carrier  140  can slide over the conduit  132  with the conduit  132  passing through the bore  144 . In some embodiments, the body  142  of the blade carrier  140  is made from a material that is the same or similar to the material of the conduit  132 . In some embodiments, the body  142  of the blade carrier  140  is made from a material that is the different from the material of the conduit  132 . For example, the body  142  of the blade carrier  140  can be made from a material (e.g., plastic) that wears more readily than the material (e.g., metal) of the conduit  132 . In the depicted embodiment, the bore  144  of the blade carrier  140  is axially aligned with the conduit  132  of the nozzle  130 . 
     The blade carrier  140  also includes a guard  146 . In the depicted embodiment, the guard  146  is coupled to one end of the body  142 . The guard  146  extends forward so that a gap exists between a portion of the body  142  and a portion of the guard  146 . In the depicted embodiment, the guard  146  extends forward beyond the front of the body  142 . In some embodiments, the gap between the portions of the body  142  and the guard  146  is sufficiently small to prevent or deter a user from inserting a finger or other body part into the gap between the portions of the body  142  and the guard  146 . 
     The blade carrier  140  is configured to hold a blade  148  in the gap between the portions of the body  142  and the guard  146 . In the depicted embodiment, the body  146  includes a slot  150  and the guard  146  includes a slot  152 . The slots  150  and  152  are arranged so that a bottom of the blade  148  can be slid into the slot  150  and a top of the blade  148  can be slide into the slot  152 . In the depicted embodiment, the blade  148  is arranged so that the blade  148  extends farther forward along the body  142  than the blade extends forward along the guard  146 . In the depicted embodiment, the blade carrier  140  includes a set screw hole  154  and a set screw  156  configured to hold the blade  148  in place with respect to the body  142  and the guard  148 . The guard  146  also includes a ball detent depression  158 . 
     To assemble the nozzle assembly  100 , the manifold block  110 , the nozzle  130 , and the blade carrier  140  can be assembled into the states shown in  FIGS. 2A and 3B ,  FIG. 3 , and  FIG. 4 , respectively. The nozzle  130  can then be coupled to the manifold block  110  by coupling an end of the conduit  132  (e.g., the end opposite from the wear cap  136 ) to the gas outlet  120  of the manifold block  110 . The blade carrier  140  can be slid over the nozzle  130  so that the bore  144  passes over portions of the conduit  132  until the blade carrier  140  comes into contact with the manifold block  110 . As the blade carrier  140  is slid along the nozzle  130 , the guard  146  can be aligned with the slot  122  on the manifold block  110  so that the guard  146  passes between the side walls  124 . The blade carrier  140  can continue sliding back along the nozzle  130  until the ball detent depression  158  is engaged with the ball detent  126 . At that point, the ball detent  126  in the ball detent depression  158  deters the blade carrier  140  from unintentionally being slid away from the manifold block  110 . The side walls  124  also deter the blade carrier  140  from rotating about the nozzle  130 . In this way, the blade carrier  140  can be added to manifold block  110  and also removed from the manifold block  110  manually in a toolless manner (i.e., without the assistance of tools). This ability to add and remove the blade carrier  140  in a toolless manner can decrease the amount of time for a user to replace the blade carrier  140  when the blade  148  needs to be replaced. 
     In some embodiments, the body  142  of the blade carrier  140  can be made from a material (e.g., plastic) that wears more readily than the material (e.g., metal) of the conduit  132 . In addition, in some embodiments, a majority of the surfaces of the nozzle assembly  100  that contact the film are on the body  142  of the blade carrier  140 . In this way, a majority of the wear of the nozzle assembly  100  due to contact from the film during normal operation will be concentrated on the body  142  of the blade carrier  140 . In other words, a majority of the wear of the nozzle assembly  100  due to contact from the film during normal operation will be on a “wear part” that is removable and replaceable in a toolless manner. 
     The nozzle assembly  100  is configured to inflate inflatable channels in an inflatable web with a closed channel and to cut open the closed channel in the inflatable web. Depicted in  FIG. 5  is an example of the nozzle assembly  100  being used to inflate and cut an inflatable web material  200 . The web material  200  includes a longitudinal edge  202 . The web material  200  is formed from two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers  206 . In some embodiments, the chambers  206  are formed in an uninflated state and the chambers  206  are capable of being inflated. In the depicted embodiment, each of the chambers  206  extends substantially transversely across the web material  200  and the pattern of the chambers  206  generally repeats in the longitudinal direction. 
     In the depicted embodiment, each of the chambers  206  includes a port  208  that is open and a distal end (not shown) that is closed. The ports  208  are located proximate the longitudinal edge so that the ports  208  repeat longitudinally along the web material  200 . The juxtaposed sheets are sealed between the ports  208  and the distal ends such that each of the chambers  206  has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers  206  are capable of being inflated by inserting a gas (e.g., air) through the ports  208 . Once the chambers  206  are inflated, the cells form three-dimensional shapes (sometimes referred to as “bubbles”) along the inflated chambers  206 . In the depicted embodiment, a pair of adjacent chambers  206  are offset so that the cells of one of the chambers  206  are aligned with the interconnecting channels of a subsequent one of the chambers  206 . 
     The web material includes a closed channel  212 . In the depicted embodiment, the closed channel  212  is located proximate the longitudinal edge  202 . In the depicted embodiment, the closed channel  212  is a “closed” channel because the two sides of the closed channel  212  are connected at the longitudinal edge  202 . In this way, the closed channel  212  forms a loop above the ports  208 . In the depicted embodiment, the closed channel  212  is in fluid communication with the chambers  206  via the ports  208 . 
     To inflate the chambers  206 , the web material  200  can be fed in a direction  230 . In the depicted embodiment, the nozzle assembly  100  is positioned so that the direction  230  of the movement of the web material  200  is substantially parallel to the axis of the body  142  of the blade carrier  140 . The web material  200  is fed so that the closed channel  212  passes over the nozzle  130  and the body  142  of the blade carrier  140 . Gas  232  is inserted into the closed channel  212  from the outlet  138  of the nozzle  130 . The gas  232  is fed from the gas source  102 , through the manifold block  110 , and through the conduit  132  before the gas  232  is inserted into the closed channel  212 . The gas  232  inserted into the closed channel  212  then passes through the ports  208  to inflate the chambers  206 . 
     In some embodiments, the nozzle assembly  100  may remain fixed and the web material  200  may be moved longitudinally in the direction  230 . In this way, the nozzle assembly  100  can sequentially inflate the chambers  206 . Coupled to the nozzle assembly  100  may be a sealing device (not shown) configured to close (e.g., seal closed) the ports  208  after inflation of the chambers  206 . In the depicted embodiment, a longitudinal seal  220  that closes the ports  208  is shown. In the depicted embodiment, the longitudinal seal  220  is created starting from a point downstream of outlet  138  of the nozzle  130 . 
     The web material  200  is fed past the nozzle assembly  100  so that a portion of the closed channel  212  passes between the body  142  and the guard  146  of the blade carrier  140 . In the depicted embodiment, the longitudinal edge  202  passes between the body  142  and the guard  146  of the blade carrier  140 . As the web material  200  moves longitudinally in the direction  230 , the portion of the closed channel  212  that passes between the body  142  and the guard  146  of the blade carrier  140  comes into contact with the blade  148  and is cut by the blade. In the depicted embodiment, the closed channel  212  is cut by the blade  148  at or near the longitudinal edge  202  to form an open channel  216 . 
     The open channel  216  is able to pass by the nozzle portion  118  of the manifold block  110 , with the two sides of the open channel  216  passing on either side of the nozzle portion  118 . In some embodiments, the nozzle portion  118  of the manifold block  110  is narrower than the mounting portion  112  of the manifold block  110 . In the depicted embodiment, the width of the nozzle portion  118  is similar to the width of the body  142 . The narrower nozzle portion  118  permits the two sides of the open channel  216  to pass on either side of the nozzle portion  118  relatively easily, while the wider mounting portion  110  has sufficient space for the gas inlet  114  to be coupled to the connector  104  and for the mounting holes  116  to be coupled to a fastener. 
     The inflation and cutting of closed-channel web materials causes the blade that cuts the closed channel to dull over time. After cutting some amount of web material, the blade is typically replaced. In some examples, the blade  148  is changed after using the blade  148  to cut through a specific number of supply rolls of the web material  200 . One benefit to the nozzle assembly  100  is that the blade  148  is easily replaceable. In some embodiments, the blade carrier  140  can be removed and replaced by an entirely new blade carrier that has a fresh blade. Because the blade carrier  140  can be removed in a toolless manner and the replacement blade carrier can be replaced in a toolless manner, the changing of the blade  148  can be done quickly and efficiently, such as when a new supply roll of the web material  200  is loaded. In other embodiments, the blade carrier  140  is removed from the manifold block  110 , the blade  148  is removed from the body  142 , and new blade is installed in place of the blade  148 , and the blade carrier  140  with the new blade is replaced back onto the manifold block  110 . In any of these examples where the blade carrier  140  is removed from the manifold block  110 , the manifold block  110  can remain mounted in place (e.g., mounted into an automated packaging station) while the blade carrier  140  is removed and replaced. This greatly reduces the amount of labor required and downtime of the machine to replace the blade  148  and/or the blade carrier  140 . 
     Depicted in  FIGS. 6A and 6B  are perspective and exploded perspective views, respectively, of another embodiment of a nozzle assembly  300  for use with closed channel web materials. The nozzle assembly  300  includes a manifold block  310 , a nozzle  330 , and a blade carrier  340 .  FIGS. 7A and 7B  depict more detailed top and bottom perspective views, respectively, of the manifold block  310 .  FIG. 8  depicts a more detailed perspective view of the nozzle  330 .  FIGS. 9A to 9C  depict more detailed perspective views of the blade carrier  340 . 
     The nozzle assembly  300  is configured to convey gas from a source of gas into a closed channel of an inflatable web material and to cut open the closed channel of the inflatable web material. In some embodiments, the source of gas is a gas line that can be coupled to a compressor, a pressure gas container (e.g., a cylinder), and the like. Also depicted in  FIGS. 6A and 6B  is a connector  304  configured to couple the source of gas to the manifold block  310 . In other embodiments, the source of gas may be connected directly to the manifold block  310  and/or coupled to the manifold block  310  via a different type of connector. 
     The manifold block  310  includes a mounting portion  312 . The mounting portion  312  of the manifold block  310  includes a gas inlet  314 . In some embodiments, the gas inlet  314  is a threaded bore into which a threaded end of the connector  304  can be coupled. In the depicted embodiment, the mounting portion  312  of the manifold block  310  includes mounting holes  316 . In some embodiments, a fastener (e.g., a bolt, a machine screw, etc.) can be inserted through each of the mounting holes  316  to mount the manifold block  310  to a structure, such as a support structure of an automated packaging station. 
     The manifold block  310  also includes a nozzle portion  318 . The nozzle portion  318  of the manifold block  310  includes a gas outlet  320 . The gas outlet  320  is in fluid communication with the gas inlet  314  so that gas that passes into the gas inlet  314  passes to the gas outlet  320 . In the depicted embodiment, the nozzle portion  318  includes a slot  322 . The slot  322  is positioned on a down-ward facing surface of the manifold block  310 . The slot  322  has side walls  324 . In some embodiments, the slot  322  is linear and extends substantially parallel to and aligned with an axis of the gas outlet  320 . The manifold block  310  also includes a ball detent  326 . In the depicted embodiment, the ball detent  326  is positioned in the slot  322 . 
     The nozzle assembly  300  includes a nozzle  330 . The nozzle  330  includes a conduit  332  that has a passageway  334  for passage of gas. The conduit  332  is configured to be coupled to the gas outlet  320  of the manifold block  310 . In some embodiments, the conduit  332  is an aluminum tube that can be pressed into the gas outlet  320  to couple the nozzle  330  to the manifold block  310 . 
     The blade carrier  340  includes a body  342  that has a bore  344 . In the depicted embodiment, the body  342  and the bore  344  are dimensioned so that the blade carrier  340  can be slid over the conduit  332  with the conduit  332  passing through the bore  344 . In some embodiments, the body  342  of the blade carrier  340  is made from a material that is the same or similar to the material of the conduit  332 . In some embodiments, the body  342  of the blade carrier  340  is made from a material that is the different from the material of the conduit  332 . For example, the body  342  of the blade carrier  340  can be made from a material (e.g., plastic) that wears more readily than the material (e.g., metal) of the conduit  332 . In the depicted embodiment, the bore  344  of the blade carrier  340  is axially aligned with the conduit  332  of the nozzle  330 . 
     The blade carrier  340  also includes a guard  346 . In the depicted embodiment, the guard  346  is coupled to one end of the body  342 . The guard  346  extends forward so that a gap exists between a portion of the body  342  and a portion of the guard  346 . In some embodiments, the gap between the portions of the body  342  and the guard  346  is sufficiently small to prevent or deter a user from inserting a finger or other body part into the gap between the portions of the body  342  and the guard  346 . 
     The blade carrier  340  is configured to hold a blade  348  in the gap between the portions of the body  342  and the guard  346 . In the depicted embodiment, the body  342  includes a slot  350  and the guard  346  includes a slot  352 . The slots  350  and  352  are arranged so that a bottom of the blade  348  can be slid into the slot  350  and a top of the blade  348  can be slide into the slot  352 . In the depicted embodiment, the blade  348  is arranged so that the blade  348  extends farther forward along the body  342  than the blade extends forward along the guard  346 . The guard  346  also includes a ball detent depression  358 . 
     The blade carrier  340  further has a wear cap  360 . In the depicted embodiment, the wear cap  360  is a portion of the body  342  that is located at a leading end of the body  342 . In this location, the wear cap  360  will be the point at which a web material will initially contact the blade carrier  340 . The wear cap  360  can have any shape. In the depicted embodiment, the wear cap  360  has a substantially spherical shape that has a diameter that is larger than the diameter of the body  342  immediately adjacent to the wear cap  360 . In some embodiments, the size and/or shape of the wear cap  360  is based on a size and/or shape of a closed channel of a web material that will be inflated by the nozzle assembly  300 . The blade carrier  340  further includes an outlet  362  through which gas can pass out of the body  342 . In the depicted embodiment, the outlet  362  is located on an opposite side of the body from the slot  350 . 
     To assemble the nozzle assembly  300 , the manifold block  310  and the blade carrier  340  can be assembled into the state shown in  FIGS. 7A and 7B  and in  FIGS. 9A to 9C , respectively. The nozzle  330  can then be coupled to the manifold block  310  by coupling an end of the conduit  332  to the gas outlet  320  of the manifold block  310 . The blade carrier  340  can be slid over the nozzle  330  so that the bore  344  passes over portions of the conduit  332  until the blade carrier  340  comes into contact with the manifold block  310 . As the blade carrier  340  is slid along the nozzle  330 , the guard  346  can be aligned with the slot  322  on the manifold block  310  so that the guard  346  passes between the side walls  324 . The blade carrier  340  can continue sliding back along the nozzle  330  until the ball detent depression  358  is engaged with the ball detent  326 . At that point, the ball detent  326  in the ball detent depression  358  deters the blade carrier  340  from unintentionally being slid away from the manifold block  310 . The side walls  324  also deter the blade carrier  340  from rotating about the nozzle  330 . In this way, the blade carrier  340  can be added to manifold block  310  and also removed from the manifold block  310  manually in a toolless manner. This ability to add and remove the blade carrier  340  in a toolless manner can decrease the amount of time for a user to replace the blade carrier  340  when the blade  348  needs to be replaced. 
     In contrast to the nozzle assembly  100 , the nozzle  330  does not extend out beyond the end of the body  342  when the nozzle assembly  300  is assembled. The conduit  332  remains inside of the bore  344  in the body  342  of the blade carrier  340 . As gas passes through the passageway  334  of the conduit  332 , the gas passes out of the passageway  334 , into the bore  344 , and then out of the outlet  362 . In this configuration, the blade carrier  340  covers the nozzle  330  prevents or deters web material from contacting the nozzle assembly. While the blade carrier  340  may be affected by wear due to the movements of web materials, the nozzle  330  would either have no wear or no significant effect from wear due to the movements of web materials. 
     The nozzle assembly  300  is configured to inflate inflatable channels in an inflatable web with a closed channel and to cut open the closed channel in the inflatable web. Depicted in  FIG. 10  is an example of the nozzle assembly  300  being used to inflate and cut an inflatable web material  400 . The web material  400  includes a longitudinal edge  402 . The web material  400  is formed from two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers  406 . In some embodiments, the chambers  406  are formed in an uninflated state and the chambers  406  are capable of being inflated. In the depicted embodiment, each of the chambers  406  extends substantially transversely across the web material  400  and the pattern of the chambers  406  generally repeats in the longitudinal direction. 
     In the depicted embodiment, each of the chambers  406  includes a port  408  that is open and a distal end (not shown) that is closed. The ports  408  are located proximate the longitudinal edge so that the ports  408  repeat longitudinally along the web material  400 . The juxtaposed sheets are sealed between the ports  408  and the distal ends such that each of the chambers  406  has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers  406  are capable of being inflated by inserting a gas (e.g., air) through the ports  408 . Once the chambers  406  are inflated, the cells form three-dimensional shapes (sometimes referred to as “bubbles”) along the inflated chambers  406 . In the depicted embodiment, a pair of adjacent chambers  406  are offset so that the cells of one of the chambers  406  are aligned with the interconnecting channels of a subsequent one of the chambers  406 . 
     The web material includes a closed channel  412 . In the depicted embodiment, the closed channel  412  is located proximate the longitudinal edge  402 . In the depicted embodiment, the closed channel  412  is a “closed” channel because the two sides of the closed channel  412  are connected at the longitudinal edge  402 . In this way, the closed channel  412  forms a loop above the ports  408 . In the depicted embodiment, the closed channel  412  is in fluid communication with the chambers  406  via the ports  408 . 
     To inflate the chambers  406 , the web material  400  can be fed in a direction  430 . In the depicted embodiment, the nozzle assembly  300  is positioned so that the direction  430  of the movement of the web material  400  is substantially parallel to the axis of the body  342  of the blade carrier  340 . The web material  400  is fed so that the closed channel  412  passes over the blade carrier  340 . Gas  432  is inserted into the closed channel  412  from the outlet  362  of the body  342 . The gas  432  is fed from the gas source, through the manifold block  310 , through the conduit  332 , and out of the outlet  362  before the gas  432  is inserted into the closed channel  412 . The gas  432  inserted into the closed channel  412  then passes through the ports  408  to inflate the chambers  406 . 
     In some embodiments, the nozzle assembly  300  may remain fixed and the web material  400  may be moved longitudinally in the direction  430 . In this way, the nozzle assembly  300  can sequentially inflate the chambers  406 . Coupled to the nozzle assembly  300  may be a sealing device (not shown) configured to close (e.g., seal closed) the ports  408  after inflation of the chambers  406 . In the depicted embodiment, a longitudinal seal  420  that closes the ports  408  is shown. In the depicted embodiment, the longitudinal seal  420  is created starting from a point downstream of the outlet  362  of the blade carrier  340 . 
     The web material  400  is fed past the nozzle assembly  300  so that a portion of the closed channel  412  passes between the body  342  and the guard  346  of the blade carrier  340 . In the depicted embodiment, the longitudinal edge  402  passes between the body  342  and the guard  346  of the blade carrier  340 . As the web material  400  moves longitudinally in the direction  430 , the portion of the closed channel  412  that passes between the body  342  and the guard  346  of the blade carrier  340  comes into contact with the blade  348  and is cut by the blade. In the depicted embodiment, the closed channel  412  is cut by the blade  348  at or near the longitudinal edge  402  to form an open channel  416 . 
     The open channel  416  is able to pass by the nozzle portion  318  of the manifold block  310 , with the two sides of the open channel  416  passing on either side of the nozzle portion  318 . In some embodiments, the nozzle portion  318  of the manifold block  310  is narrower than the mounting portion  312  of the manifold block  310 . In the depicted embodiment, the width of the nozzle portion  318  is similar to the width of the body  342 . The narrower nozzle portion  318  permits the two sides of the open channel  416  to pass on either side of the nozzle portion  318  relatively easily, while the wider mounting portion  310  has sufficient space for the gas inlet  314  to be coupled to the connector  304  and for the mounting holes  316  to be coupled to a fastener. 
     The inflation and cutting of closed-channel web materials causes the blade that cuts the closed channel to dull over time. After cutting some amount of web material, the blade is typically replaced. In some examples, the blade  348  is changed after using the blade  348  to cut through a specific number of supply rolls of the web material  400 . One benefit to the nozzle assembly  300  is that the blade  348  is easily replaceable. In some embodiments, the blade carrier  340  can be removed and replaced by an entirely new blade carrier that has a fresh blade. Because the blade carrier  340  can be removed in a toolless manner (i.e., without the assistance of tools) and the replacement blade carrier can be replaced in a toolless manner, the changing of the blade  348  can be done quickly and efficiently, such as when a new supply roll of the web material  400  is loaded. In other embodiments, the blade carrier  340  is removed from the manifold block  310 , the blade  348  is removed from the body  342 , and new blade is installed in place of the blade  348 , and the blade carrier  340  with the new blade is replaced back onto the manifold block  310 . In any of these examples where the blade carrier  340  is removed from the manifold block  310 , the manifold block  310  can remain mounted in place (e.g., mounted into an automated packaging station) while the blade carrier  340  is removed and replaced. This greatly reduces the amount of labor required and downtime of the machine to replace the blade  348  and/or the blade carrier  340 . 
     In some embodiments, the body  342  of the blade carrier  340  can be made from a material (e.g., plastic) that wears more readily than the material (e.g., metal) of the conduit  332 . In addition, in some embodiments, a majority of the surfaces of the nozzle assembly  300  that contact the film are on the body  342  of the blade carrier  340 . In this way, a majority of the wear of the nozzle assembly  300  due to contact from the film during normal operation will be concentrated on the body  342  of the blade carrier  340 . In other words, a majority of the wear of the nozzle assembly  300  due to contact from the film during normal operation will be on a “wear part” that is removable and replaceable in a toolless manner. 
     Depicted in  FIGS. 11A, 11B, and 11C  are exploded perspective, side, and top views, respectively, of an embodiment of a nozzle assembly  500  for use with closed channel web materials. The nozzle assembly  500  includes a manifold block  510 , a nozzle  530 , and a blade carrier  540 . The nozzle assembly  500  is configured to convey gas from a gas source into a closed channel of an inflatable web material and to cut open the closed channel of the inflatable web material. In some embodiments, the gas source can be a gas line that can be coupled to a compressor, a pressure gas container (e.g., a cylinder), and the like. In some embodiments, the gas source may be connected directly to the manifold block  510  and/or coupled to the manifold block  510  via a connector. 
     The manifold block  510  includes a mounting portion  512 . The mounting portion  512  of the manifold block  510  includes a gas inlet  514 . In some embodiments, the gas inlet  514  is a threaded bore into which a threaded end of a connector can be coupled. In the depicted embodiment, the mounting portion  512  of the manifold block  510  includes mounting holes  516 . In some embodiments, a fastener (e.g., a bolt, a machine screw, etc.) can be inserted through each of the mounting holes  516  to mount the manifold block  510  to a structure, such as a support structure of an automated packaging station. The manifold block  510  also includes a nozzle portion  518 . The nozzle portion  518  of the manifold block  510  includes a gas outlet  520 . The gas outlet  520  is in fluid communication with the gas inlet  514  so that gas that passes into the gas inlet  514  passes to the gas outlet  520 . In the depicted embodiment, the nozzle portion  518  includes mounting holes  516  that allow the blade carrier  540  to be mounted to the manifold block  510 . 
     The nozzle assembly  500  includes a nozzle  530 . The nozzle  530  includes a conduit  532  that has a passageway  534  for passage of gas. The conduit  532  is configured to be coupled to the gas outlet  520  of the manifold block  510 . In some embodiments, the conduit  532  is an aluminum tube that can be pressed into the gas outlet  520  to couple the nozzle  530  to the manifold block  510 . In some embodiment, an end of the conduit  532  includes external threads that can be threaded into internal threads of the gas outlet  520  to couple the nozzle  530  to the manifold block  510 . 
     In the depicted embodiment, the nozzle  530  includes a wear cap  536  that forms an outlet  538 . In the depicted embodiment, the wear cap  536  is couplable to a distal end of end of the conduit  532  (e.g., an end of the conduit  532  opposite of the end of the conduit  532  that is coupled to the gas outlet  520 ). The wear cap  536  may contact a web material that is fed past the nozzle assembly  500 , resulting in greater wear on the wear cap  536  than on other parts of the nozzle  530 , such as the conduit  532 . In some embodiments, the conduit  532  is made from a material (e.g., a metal, such as aluminum) that is more durable than a material (e.g., plastic) of the wear cap  536 . In this way, the wear cap  536  may be a “wear part” that is intended to be replaced periodically but has a relatively low cost compared to the conduit  532 . In the depicted embodiment, the wear cap  536  is configured to close off the end of the conduit  532 . 
     The blade carrier  540  includes a body  542  that is couplable to the manifold block  510 . In the depicted embodiment, the body  542  is couplable to the manifold block  510  via fasteners  541 . In the depicted embodiment, the nozzle portion  518  of the manifold block  510  includes mounting holes  519  configured to receive the fasteners  541  such that the blade carrier  540  is configured to be coupled to the nozzle portion  518  of the manifold block  510 . In some embodiments, the body  542  of the blade carrier  540  is made from a material that is the same or similar to the material of the conduit  532 . In some embodiments, the body  542  of the blade carrier  540  is made from a material that is the different from the material of the conduit  532 . For example, the body  542  of the blade carrier  540  can be made from a material (e.g., plastic) that wears more readily than the material (e.g., metal) of the conduit  532 . 
     The blade carrier  540  also includes a guard  546 . In the depicted embodiment, the guard  546  is coupled to one end of the body  542 . The guard  546  extends forward so that a gap exists between the guard  546  and the conduit  532 . In the depicted embodiment, the guard  546  extends forward beyond the front of the body  542 . In some embodiments, the gap between the guard  546  and the conduit  532  is sufficiently small to prevent or deter a user from inserting a finger or other body part into the gap between the guard  546  and the conduit  532 . 
     The blade carrier  540  is configured to hold a blade  548  in the gap between the portions of the body  542  and the guard  546 . In the depicted embodiment, the conduit  532  includes a slot  550 . In the depicted embodiment, the slot  550  is arranged so that, as the blade carrier is coupled to the manifold block  510 , a bottom of the blade  548  slides into the slot  550 . In the depicted embodiment, the blade  548  is arranged so that the blade  548  extends farther forward along the conduit  532  than the blade extends forward along the guard  546 . In the depicted embodiment, the blade carrier  540  is removably couplable to the manifold block  510  so that, when the blade  548  will be replaced, the blade carrier  540  can be removed. At that point, the blade  548  can be removed from the blade carrier  540  and replaced with a new blade before the blade carrier  540  is again coupled to the manifold block. Alternatively, the entire blade carrier  540  (including the blade  548 ) can be discarded and a new blade carrier with a new blade can be coupled to the manifold block  110 . 
     For purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value. 
     The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. 
     Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.