Patent Description:
A variety of inflated cushions are well known and used for sundry packaging applications. For example, inflated cushions are often used as protective 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. A typical type of inflated cushions is 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 and thereafter sealed to inhibit or prevent release of the air or gas.

In the process of inflating and sealing the chambers, the films are sealed by a variety of heating apparatuses. In traditional systems, the temperatures and pressures on the seals are not sufficiently controlled after the seal is made. Poor post seal control leads to increased packaging failure. As such, improved heating and cooling paths and protection for the seal are therefore desirable. <CIT> describes a machine for converting a web of preformed pouches to dunnage units. <CIT> describes a sealer with means for localized heating to bond film material. <CIT> describes a device for sealing two plies of film together, particularly for enclosing a foamable composition in a flexible container.

Aspects of the present invention are defined by the independent claim below to which reference should now be made. Optional features are defined by the dependent claims.

Embodiments of the present disclosure may include a protective packaging formation device. The device can include an inflation assembly having a fluid conduit that directs fluid between first and second overlapping plies of a web material. The device can include a driving mechanism that drives the film in a downstream direction through an arcuate pinch zone. The device can include a sealing mechanism that includes a heating element that includes a wide cross-section portion and a reduced cross-section portion, the size of the cross-sections selected such that the reduced cross-section portion produces high temperature zone that outputs sufficient heat to heat seal the plies to create a longitudinal seal that seals the first and second plies of film together, trapping the fluid therebetween as the driving mechanism drives the web past the heating assembly in a downstream direction.

In accordance with various embodiments, the heating element can be supported on the heater support structure, which defines a support surface that applies pressure to the web against an opposing compression element. The heater support structure includes an insulating member that includes at least a portion of the support surface, along which the support surface has an arcuate profile. The heater may include a first conducting member separated from a second conducting member, and the heating element has a first end and a second end, with each end mounted to the separate conducting members. The heating element may be laid over the insulating member with the reduced cross-section laid across the insulating member.

In accordance with various embodiments, the heating element may be laid over portions of the conducting members with larger cross section portion of the heating element being laid across the portions of the conducting members. The reduced cross-section portion of the heating element may occupy more of the first half of the pinch zone than the second half. The heating element may extend along both the heat zone and the cooling zone. The drive mechanism may include a belt and the web is separated from the heater by the belt. The drive mechanism may include a first belt and a second belt that advance the web through the pinch zone. The wide cross-section portion has a heat output that is insufficient to heat seal the plies together. The wide cross-section of the heating element may extend into the cooling zone.

Embodiments of the present disclosure may include protective packaging formation device. The device can include an inflation assembly having a fluid conduit that directs fluid between first and second overlapping plies of a web material. The device can include a sealing mechanism. The sealing mechanism includes a heating zone and a cooling zone, wherein the heating zone is operable to heat the plies to create a longitudinal heat seal that seals the first and second plies together as the web is driven over the heating zone in a downstream direction, and the cooling zone disposed downstream of the heating zone operable to allow the heated plies to cool at the longitudinal heat seal as the web is driven over the heating zone in a downstream direction, such that the cooled longitudinal heat seal retains the fluid between the plies. The device include a heating element that extends along both the heating zone and the cooling zone, with the heating element having a first profile in the heating zone and a second profile in the cooling zone. The device may include a driving mechanism that drives the film in the downstream direction over the heating and cooling zones, with the web supported by a web-support surface from an upstream location to a downstream location.

In accordance with various embodiments, the sealing mechanism includes a heater support structure that defines the web-support surface with a heating element that extends from an upstream portion of the web-support surface to a downstream portion of the web-support surface. The sealing mechanism may include a pinch zone that overlaps longitudinally with the heating zone and cooling zone, the pinch zone being defined between opposing compression elements. The heating element may extend the entire length of the pinch zone. The heating element may be a nichrome foil heater that follows the web-support surface through the pinch zone. The heating element may include a high heat zone that is laid over the insulating member and a low heat zone located along at least one of the electrically conductive supports. The high heat zone is defined by a length of the heating element with a reduced cross section. The difference between the first profile and the second profile may be a change in cross-section of the heating element.

The present disclosure is related to protective packaging and systems and methods for converting inflatable material into inflated cushions that may be used as cushioning or protection for packaging and shipping goods.

As shown in <FIG>, a multi-ply flexible web material <NUM> for inflatable cushions <NUM> is provided. The web material <NUM> includes a first film ply <NUM> having a first longitudinal edge <NUM> and a second longitudinal edge <NUM>, and a second film ply <NUM> having a first longitudinal edge <NUM> and a second longitudinal edge <NUM>. The second ply <NUM> is aligned to be over lapping and can be generally coextensive with the first ply <NUM>, i.e., at least respective first longitudinal edges <NUM>, <NUM> are aligned with each other and/or second longitudinal edges <NUM>, <NUM> are aligned with each other. In some embodiments, the plies can be partially overlapping with inflatable areas in the region of overlap.

<FIG> illustrates a top view of the web material <NUM> having first and second plies <NUM>, <NUM> joined to define a first longitudinal edge <NUM> and a second longitudinal edge <NUM> of the web material <NUM> (also referred to as film <NUM>). The first and second plies <NUM>, <NUM> can be formed from a single sheet of flexible material, a flattened tube of flexible material with one edge having a slit or being open, or two sheets of flexible material which may be sealed along the longitudinal edges <NUM>, <NUM> to define the longitudinal edge <NUM> of the flexible structure <NUM>. For example, the first and second plies <NUM>, <NUM> can include a single sheet of flexible material that is folded to define the joined second edges <NUM>, <NUM> (e.g., "c-fold film"). In a more particular example, edges <NUM>, <NUM> are at the c-fold in such an embodiment. Alternatively, for example, the first and second plies <NUM>, <NUM> can include a tube of flexible material (e.g., a flatten tube) that is slit along the aligned first longitudinal edges <NUM>, <NUM>. Also, for example, the first and second plies <NUM>, <NUM> can include two independent sheets of flexible material joined, sealed, or otherwise attached together along the aligned second edges <NUM>, <NUM>.

The web material <NUM> can be formed from any of a variety of flexible web materials known to those of ordinary skill in the art. Such web materials include, but are not limited to, ethylene vinyl acetates (EVAs), metallocenes, polyethylene resins such as low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and high density polyethylene (HDPE), and blends thereof. Other materials and constructions can be used. The disclosed web material <NUM> can be rolled on a hollow tube, a solid core, or folded in a fan folded box, or in another desired form for storage and shipment.

As shown in <FIG>, the web material <NUM> can include a series of transverse seals <NUM> disposed along the longitudinal extent of the web material <NUM>. Each transverse seal <NUM> extends from the longitudinal edge <NUM> towards an inflation channel <NUM>. In the embodiment shown, the inflation channel <NUM> extends along the longitudinal edge <NUM> opposite the longitudinal edge <NUM>, and thus the transverse seal <NUM> extends from the longitudinal edge <NUM> toward the first longitudinal edge <NUM>. In some embodiments, the flexible structure <NUM>, may include an inflation channel <NUM> located elsewhere in relation to the longitudinal edge(s) <NUM> and/or <NUM>. For example, the inflation channel may extend along the length of the structure <NUM> at an intermediate location (e.g., midway) between the longitudinal edge(s) <NUM> and/or <NUM>. In some embodiments, the flexible structure <NUM> may, additionally or alternatively, include an inflation channel <NUM> along the longitudinal edge <NUM>. In the illustrated embodiment, each transverse seal <NUM> has a first end <NUM> proximate the second longitudinal edge <NUM> and a second end <NUM> spaced a transverse dimension d from the first longitudinal edge <NUM> of the film <NUM>. A chamber <NUM> is defined within a boundary formed by the seal or fold at longitudinal edge <NUM> and pair of adjacent transverse seals <NUM>.

Each transverse seal <NUM> of the embodiment in <FIG> is substantially straight and extends substantially perpendicular to the second longitudinal edge <NUM>. In other embodiments, other arrangements of the transverse seals <NUM> may be used. For example, in some embodiments, the transverse seals <NUM> may have undulating or zigzag patterns.

The transverse seals <NUM> as well as sealed longitudinal edges <NUM>, <NUM> can be formed by 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 <NUM>, can be provided. The longitudinal inflation channel <NUM>, as shown in <FIG>, may be disposed between the second end <NUM> of the transverse seals <NUM> and the first longitudinal edge <NUM> of the film. Preferably, the longitudinal inflation channel <NUM> extends longitudinally along the longitudinal side <NUM> and an inflation opening <NUM> is disposed on at least one end of the longitudinal inflation channel <NUM>. The longitudinal inflation channel <NUM> has a transverse width D. In the preferred embodiment, the transverse width D is substantially the same as the transverse dimension d between the longitudinal edge <NUM> and second ends <NUM> of the transverse seals <NUM>. It is appreciated, however, that in other configurations, a different transverse width D may be used.

The longitudinal edge <NUM> and transverse seals <NUM> cooperatively define boundaries of inflatable chambers <NUM>. As shown in <FIG>, each inflatable chamber <NUM> is in fluid communication with the longitudinal inflation channel <NUM> via a mouth (e.g. opening <NUM>) opening towards the longitudinal inflation channel <NUM>, thus permitting inflation of the inflatable chambers <NUM> as further described herein.

In one embodiment, the flexible structure <NUM> may further include seal extensions <NUM> adjacent or connected to a respective transverse seal <NUM> and extending toward or into the respective inflatable chamber(s) <NUM>. The seal extensions <NUM> define perpendicularly lower regions of the chamber corresponding to smaller width or restrictions in the width of the chamber, which creates bendable areas, which can be aligned to create the bendable lines, thereby increasing the flexibility of web material <NUM> such that it can be more easily bent or folded. Such flexibility allows for the film <NUM> to wrap around regular and irregular shaped objects. The chamber portions <NUM> are in fluid communication with adjacent chamber portions <NUM> as well as with the inflation channel <NUM>. The seal extensions can be any shape (e.g., rectangular as shown, circular, ovular, or having any other regular or irregular shape) or size. In accordance with some embodiments, the transverse seals <NUM> are continuous, without interruptions from seal extensions or the like.

In some embodiments, the film <NUM> includes weakened portions <NUM> (e.g., lines of weakness, such as perforation lines) disposed along the longitudinal extent of the film <NUM> and extending transversely across the first and second plies of the film <NUM>. Each weakened portion <NUM> extends from the second longitudinal edge <NUM> and towards the first longitudinal edge <NUM>, e.g., partially or fully along the length of the transverse seals <NUM>. In the illustrated embodiment, the weekend portions <NUM> are in the form of transverse lines of weakness and each transverse line of weakness in the flexible structure <NUM> is disposed between a pair of adjacent chambers <NUM>. For example, each line of weakness <NUM> may be disposed between two adjacent transverse seals <NUM> and between two adjacent chambers <NUM>, as depicted in <FIG>. The transverse lines of weakness <NUM> facilitate separation of adjacent inflatable cushions <NUM>. In some embodiments, thicker transverse seals <NUM> may be used, which define a transverse sealed portion and the weakened portions <NUM> may be provided along, at least part of the transverse sealed portion of the flexible structure <NUM>.

The weakened portions <NUM> may be provided in a variety of configurations known by those of ordinary skill in the art. For example, in some embodiments, the weakened portions <NUM> may be provided as transverse lines of weakness <NUM> (e.g., as shown in <FIG>) and may 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. The lands form small connections across the weakened portion. Alternatively, for example, in some embodiments, the weakened portions <NUM> may include score lines or the like formed in the flexible structure <NUM>.

The transverse lines of weakness <NUM> can be formed by a variety of techniques known to those of ordinary skill in the art. Such techniques include, but are not limited to, cutting (e.g., techniques that use a cutting or toothed element, such as a bar, blade, block, roller, wheel, or the like) and/or scoring (e.g., techniques that reduce the strength or thickness of material in the first and second plies, such as electromagnetic (e.g., laser) scoring and mechanical scoring).

Preferably, the transverse width <NUM> of the inflatable chamber <NUM> is typically less than <NUM> inches. Generally, the transverse width <NUM> is <NUM> inches up to about <NUM> inches, more preferably about <NUM> inches up to about <NUM> inches wide, and most preferably about <NUM> inches. The longitudinal length <NUM> between weakened portions <NUM> is typically less than <NUM> inches. Generally the length <NUM> between weakened portions <NUM> is at least about <NUM> inches up to about <NUM> inches, more preferably at least about 5inches up to about <NUM> inches, and most preferably at least about <NUM> inches up to about <NUM> inches. In addition, the inflated heights of each inflated chamber <NUM> can be at least about <NUM> inches up to about <NUM> inches, and in some cases up to about <NUM> inches. It is appreciated that other suitable dimensions can be used.

Turning now to <FIG>, an inflation and sealing device <NUM> for converting the flexible structure <NUM> of uninflated material into a series of inflated pillows or cushions <NUM> is provided. The uninflated flexible structure <NUM> can be a bulk quantity of supply, uninflated material <NUM>. For example, as shown in <FIG>, the uninflated flexible structure <NUM> can be provided as a roll of supply material <NUM>, which may be rolled around an inner support tube. In some embodiments, the supply material may be rolled into a roll with a hollow center. The support tube or hollow center of the roll of material <NUM> may be supported on a supply support element <NUM>, in this case a roll axle <NUM>, of the inflation and sealing device <NUM>. The roll axle <NUM> accommodates the center or tube of the roll of web material <NUM>. In other embodiments, different structures can be used to support the roll of material, such as a tray, fixed spindle or multiple rollers, or a supply material of different configuration (e.g., folded supply material). <FIG> show the inflation and sealing device <NUM> without the flexible structure <NUM>, such as the web material <NUM>, loaded on the device. In some embodiments, the flexible structure <NUM> of uninflated material is delivered from a folded form such as a fanfolded configuration.

In accordance with various embodiments, the inflation and sealing device <NUM> may include handling elements, with each of the handling elements including film-supporting portions. The film-support portions may support and direct an inflatable web of material in a longitudinal direction along a path (e.g., path E in <FIG>). The handling elements may include a supply support element <NUM> that supports a supply <NUM> of the film <NUM> in an uninflated state. An inflation and sealing assembly <NUM> may be operable to inflate the film with a fluid by directing the fluid between superimposed plies <NUM>, <NUM> of the film <NUM> and to seal the plies <NUM>, <NUM> together to seal the fluid therein. Two of the film-supporting portions (e.g., a roll axle <NUM> and guide member <NUM>) may be arranged relative to a supporting structure <NUM> and each other such that the supply material experiences a different amount of tension along the transverse direction as it passes from the first to the second film-supporting portion. The relative position of the two film-supporting portions may cause a difference in tautness (or tension) in two portions of the web disposed transversely of each other in a substantially same longitudinal location along the path. In further embodiments of the present disclosure, the differential tension may be achieved by providing the guide member <NUM> with one or more expansion elements as described further below. In some examples, the resulting shape of the guide member <NUM> may be configured to define a slightly shorter longitudinal travel distance between the first and second adjacent film-supporting portions at one transverse end of the film as compared to the longitudinal travel distance between the first and second adjacent film-supporting portions at another (e.g., opposite) transverse location of the film, as will be further described.

Referring back to <FIG>, the inflation and sealing device <NUM> may include a bulk material support <NUM>. The bulk quantity of uninflated material may be supported by the bulk material support <NUM>. 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 supply of web material. The bulk material support may include a single roller that accommodates the center of the roll of web material <NUM>, e.g., as shown in <FIG>. In this example, the bulk support material may be a roll axle or spindle <NUM> passing through the core or center of the roll of the material <NUM>. Typically, the core is made of cardboard or other suitable materials. The bulk material support <NUM> may rotate about an axis Y.

The web material <NUM> is pulled by a drive mechanism160. In some embodiments, intermediate members such as a guide member <NUM> (e.g., which may include a fixed rod, or a roller) can be positioned between roll <NUM> and the drive mechanism <NUM>. For example, the optional guide member <NUM> can extend generally perpendicularly from a support structure <NUM>. The guide member <NUM> can be positioned to guide the flexible structure <NUM> away from the roll of material <NUM> and along a material path "B" along which the material is processed, also referred to as longitudinal path. As shown in <FIG>, the guide member <NUM> is arranged between the material support <NUM>, which supports the supply material, and the inflation and sealing components of the device <NUM>. The guide member <NUM> may be arranged to route the film <NUM> from the supply toward the inflation and sealing assembly such that the film <NUM> follows a curved longitudinal path. The guide member <NUM> may include one or more surfaces, which define film-supporting surfaces (e.g., surfaces extending along the side of the guide member around which the film bends as it traverses the path B). In some examples, and as described further below, the guide member <NUM> may include one or more expansion elements. The one or more expansion elements provide at least a portion of the film-supporting surface of the guide member and can configure the guide member to provide variable tension on the film <NUM> at different transverse locations of the film <NUM>.

The guide member <NUM> or a portion thereof may be movably coupled to the inflation and sealing device <NUM>, such that the guide member <NUM> or the movable portion thereof can move (e.g., spin, translate, oscillate, etc.) in relation to the support structure <NUM> when the film <NUM> is being drawn from the roll <NUM> by drive mechanism <NUM>. In some examples, the guide member <NUM> may include a guide roller, which includes an axle or rod portion <NUM> and a rotatable or roller portion <NUM> coaxially coupled to the rod portion <NUM> such that the roller portion <NUM> spins about a common axis <NUM> of the rod and roller portions. The roller portion <NUM> may provide a film-supporting surface <NUM> that supports the film <NUM>, in this case moving with the film <NUM> as it is being drawn from the roll <NUM>. The moving film-supporting surface <NUM> may reduce or eliminating sliding friction between the guide member <NUM> and the film <NUM>. However, guide members with a fixed film-supporting surface <NUM> are also envisioned. For example, the guide member may include a rod similar to the axle <NUM> without the rotatable portion <NUM>. A low friction material, such as polytetrafluoroethylene (PTFE), may be provided (e.g., in the form of a coating or a strip of material adhered to) on at least a portion of the film-supporting surface <NUM> of a non-rotatable rod, to reduce sliding friction. In yet other embodiments, the non-rotatable portion or rod of the guide member and the rotatable portion (e.g., roller) may not be coextensive. For example, the only rotating portion of the guide member <NUM> may be the expansion element <NUM>. Film-supporting surface(s) of the guide member which do not rotate as the film is traveling over the guide member may be coated or otherwise provided with friction-reducing material(s).

In some embodiments, the guide member <NUM> may additionally or alternatively be coupled to the device <NUM> such that it moves in a direction normal to the longitudinal path B traveled by the supply material, as indicated by arrow <NUM> in <FIG>. Such movement may be used to relieve an increase in tension experienced by the supply material as it travels along path E. For example, the guide member <NUM> may be spring-loaded or biased toward a first side <NUM> of the support structure <NUM> in its nominal state (e.g., when unloaded or operating under normal tension of the supply material). An increase in tension experienced by the film <NUM> along the portion between the supply end and the pinch zone towards may be relieved by a downward movement of the guide member <NUM> against the spring force. The spring constant may be selected to apply a sufficient amount of biasing force against the film to maintain the film taut while being sufficiently soft to prevent the tension in the film exceeding a threshold, which may damage the film and/or the device <NUM>. A guide roller <NUM> movably coupled to the device <NUM> in this manner may be interchangeably referred to as a dancer roller.

A guide member <NUM> according to the present disclosure may include one or more expansion elements <NUM> as will be described further below. In some embodiments, the expansion element <NUM> may provide some or all of the film-supporting surface <NUM> of the guide member <NUM>. A guide member <NUM> according to the principles of the present disclosure may thus be configured to control the material <NUM>, such as to prevent or reduce sagging of the film <NUM> between the roll <NUM> and the inflation nozzle <NUM> of the device <NUM>.

In various embodiments, the stock material (e.g. web material <NUM>) may advance downstream from the stock roll of material (e.g., roll of material <NUM>) without engaging a guide roll but may instead be advanced directly into an inflation and sealing assembly <NUM>.

It is appreciated that other suitable structures may be utilized in addition to or as an alternative to use of brakes, guide rollers, or web feed mechanisms in order to guide the web material <NUM> toward a pinch area <NUM> which can form part of the sealing assembly <NUM>. As indicated, because the web material <NUM> may sag, bunch up, drift along the guide roller <NUM>, shift out of alignment with the pinch zone <NUM>, alternate between tense and slack, or become subject to other variations in delivery, the inflation and sealing assembly <NUM> may need suitable adjustability to compensate for these variations. For example, a nozzle <NUM> may be at least partially flexible, allowing the nozzle <NUM> to adapt to the direction the web material <NUM> approaches as the structure is fed towards and over the nozzle <NUM>, thereby making the nozzle <NUM> operable to compensate for or adapt to variations in the feed angle, direction, and other variations that the web material <NUM> encounters as it is fed towards and over the nozzle <NUM>. In some examples, as described above, the guide roller <NUM> may be transversely movable relative to the sealing assembly <NUM> such as to adjust or eliminate any variations in delivery of the supply material.

The inflation and sealing device <NUM> includes an inflation and sealing assembly <NUM>. Preferably, the inflation and sealing assembly <NUM> is configured for continuous inflation of the web material <NUM> as it is unraveled from the roll <NUM>. The roll <NUM>, preferably, comprises a plurality of chain of chambers <NUM> that are arranged in series. To begin manufacturing the inflated pillows from the web material <NUM>, the inflation opening <NUM> of the web material <NUM> is inserted around an inflation assembly, such as an inflation nozzle <NUM>, and is advanced along the material path "E". In the embodiment shown in <FIG>, preferably, the web material <NUM> is advanced over the inflation nozzle <NUM> with the chambers <NUM> extending transversely with respect to the inflation nozzle <NUM> and side outlets <NUM>. The side outlets <NUM> may direct fluid in a transverse direction with respect to a nozzle base <NUM> into the chambers <NUM> to inflate the chambers <NUM> as the web material <NUM> advanced along the material path "E" in a longitudinal direction. The inflated web material <NUM> is then sealed by the sealing assembly <NUM> in the sealing area <NUM> to form a chain of inflated pillows or cushions <NUM>.

The side inflation area <NUM> (shown in <FIG>) is shown as the portion of the inflation and sealing assembly along the path "E" adjacent the side outlets <NUM> in which air from the side outlets <NUM> can inflate the chambers <NUM>. In some embodiments, the inflation area <NUM> is the area disposed between the inflation tip <NUM> and pinch area <NUM>. The web material <NUM> is inserted around the inflation nozzle <NUM> at the nozzle tip <NUM>, which is disposed at the forward most end of the inflation nozzle <NUM>. The inflation nozzle <NUM> inserts a fluid, such as pressured air, into the uninflated web material <NUM> material through nozzle outlets, inflating the material into inflated pillows or cushions <NUM>. The inflation nozzle <NUM> can include a nozzle inflation channel that fluidly connects a fluid source, which enters at a fluid inlet, with one or more nozzle outlets (e.g. side outlet <NUM>). It is appreciated that in other configurations, the fluid can be other suitable pressured gas, foam, or liquid. The nozzle may have an elongated portion, which may include one or more of a nozzle base <NUM>, a flexible portion, and/or a tip <NUM>. The elongated portion may guide the flexible structure to a pinch area <NUM>. At the same time the nozzle may inflate the flexible structure through one or more outlets. The one or more outlets may pass from the inflation channel out of one or more of the nozzle base <NUM> (e.g. outlet <NUM>), the flexible portion 142a, or the tip <NUM>. The inflation nozzle <NUM> may extend away from the front surface of the housing.

As shown in <FIG>, the side outlet <NUM> can extend longitudinally along the nozzle base <NUM> toward a longitudinal distance from the inflation tip <NUM>. In various embodiments, the side outlet <NUM> originates proximate, or in some configurations, overlapping, the sealer assembly such that the side outlet <NUM> continues to inflate the inflatable chambers <NUM> about right up to the time of sealing. This can maximize the amount of fluid inserted into the inflatable chambers <NUM> before sealing, and minimizes the amount of dead chambers, i.e., chambers that do not have sufficient amount of air. Although, in other embodiments, the slot outlet <NUM> can extend downstream past the entry pinch area <NUM> and portions of the fluid exerted out of the outlet <NUM> is directed into the web material <NUM>. As used herein, the terms upstream and downstream are used relative to the direction of travel of the web material <NUM>. The beginning point of the web is upstream and it flows downstream as it is inflated, sealed, cooled and removed from the inflation and sealing device.

The length of the side outlet <NUM> may be a slot having a length that extends a portion of the inflation nozzle <NUM> between the tip <NUM> and the entry pinch area <NUM>. In one example, the slot length may be less than half the distance from the tip <NUM> to the entry pinch area <NUM>. In another example, the slot length may be greater than half the distance from the tip <NUM> to the pinch area <NUM>. In another example, the slot length may be about half of the distance from the tip <NUM> to the pinch area <NUM>. The side outlet <NUM> can have a length that is at least about <NUM>% of the length of the inflation nozzle <NUM>, for example, and in some embodiments at least about <NUM>% of the length of the inflation nozzle <NUM>, or about <NUM>% of the length of the inflation nozzle <NUM>, although other relative sizes can be used. The side outlet <NUM> expels fluid out the lateral side of the nozzle base <NUM> in a transverse direction with respect to the inflation nozzle <NUM> through the mouth <NUM> of each of the chambers <NUM> to inflate the chambers <NUM>. The tip of the inflation nozzle can be used to pry open and separate the plies in an inflation channel at the tip as the material is forced over the tip. For example, when the web is pulled over traditional inflation nozzles, the tip of the traditional inflation nozzles forces the plies to separate from each other. A longitudinal outlet may be provided in addition to or in the absence of the lateral outlet, such as side outlet <NUM>, which may be downstream of the longitudinal outlet and along the longitudinal side of the nozzle wall of the nozzle base <NUM> of the inflation nozzle <NUM>.

The flow rate of the fluid through the nozzle <NUM> form the blower <NUM> is typically about <NUM> to <NUM> cfm. But much higher flow rates can be used, for example, when a higher flow rate fluid source is used, such as, the blower <NUM> can have a flow rate in excess of <NUM> cfm.

<FIG>, <FIG> and <FIG> illustrate a side views of the inflation and sealing assembly <NUM>. As shown in <FIG>, the fluid source can be disposed behind a cover <NUM> or other structural support for the nozzle and sealing assemblies including a housing plate <NUM> on which the cover <NUM> mounts. The cover <NUM> includes a sealing and inflation assembly opening 184a as shown in <FIG>. The fluid source (e.g. from blower <NUM>) is connected to and feeds the fluid inflation nozzle conduit. The web material <NUM> is fed over the inflation nozzle <NUM>, which directs the web to the inflation and sealing assembly <NUM>.

While various examples are described herein and shown in the <FIG>, it should be appreciated that these examples should not be limiting and that the nozzle <NUM> and inflation assembly may be configured in accordance with any known embodiments or developed embodiments that may benefit from the disclosure herein as a person of ordinary skill in the art could apply based on the disclosure herein.

Preferably, the web material <NUM> is continuously advanced through the sealing assembly along the material path "E" and past the heating assembly <NUM> at a pinch area <NUM> to form a continuous longitudinal seal <NUM> along the web material <NUM> by sealing the first and second plies <NUM>,<NUM> together. The longitudinal seal <NUM> is shown as the phantom line in <FIG>. Preferably, the longitudinal seal <NUM> is disposed a transverse distance from the first longitudinal edge <NUM>, <NUM>, and most preferably the longitudinal seal <NUM> is disposed along the mouths <NUM> of each of the chambers <NUM>.

The web material <NUM> is advanced or driven through the inflation and sealing assembly <NUM> by a drive mechanism <NUM>. The inflation and sealing assembly <NUM> may incorporate the drive mechanism or the two systems may operate independently. The drive mechanism <NUM> includes one or more devices operable to motivate the flexible structure through the system. For example, the drive mechanism includes one or more motor driven rollers operable to drive the flexible material <NUM> in a downstream direction along a material path "E", such as those disclosed in <CIT>. One or more of the rollers or drums are connected to the drive motor such that the one or more rollers drive the system. In accordance with various embodiments, the drive mechanism <NUM> drives the web material <NUM> without a belt contacting the flexible structure or in some embodiments, the entire system is beltless. In another example, the system has a belt that does not contact the web material <NUM> but instead drives the rollers. In another example, the system has a belt on some drive elements but not others, such as those disclosed in <CIT> In other example, the system may have belts interwoven throughout the rollers allowing the material to be driven through the system by the belts. For example, <CIT> discloses a system that utilizes belts and rollers to control the inflation and sealing of cushions <NUM> and the disclosure provided herein may be utilized with such a system.

In accordance with various embodiments, the drive mechanism <NUM> includes opposing compression mechanisms <NUM> and <NUM>. As illustrated in <FIG>, the compression mechanism <NUM> is positioned adjacent to the compression mechanism <NUM>. The compression mechanism <NUM> is positioned relative to the compression mechanism <NUM> such that the two compression mechanisms <NUM>, <NUM> together are operable to receiving the flexible material <NUM> at a pinch area <NUM>. The pinch area <NUM> is defined by the area in which the compression mechanism <NUM> and the compression mechanism <NUM> are positioned against the web material <NUM> to pinch the web material <NUM> there between. The pinch area <NUM> can extend from A to B shown in <FIG>.

The drive mechanism <NUM> can also include other compression mechanisms. The other compression mechanisms would also positioned adjacent to the compression mechanism <NUM> or the compression mechanism <NUM>. The relationship between the other compression mechanisms and the compression mechanism <NUM> or <NUM> can be such that the two compression mechanisms form a second pinch area or extend the pinch area <NUM> in which the compression mechanisms contact and apply pressure to the web material <NUM>.

In accordance with various embodiments, the drive system forms a cooling zone <NUM> that is disposed contemporaneously with or downstream of the pinch area <NUM>. In accordance with a particular example as shown in <FIG>, the pinch area <NUM> includes a heating zone <NUM> and a cooling zone <NUM>. The cooling zone <NUM> is defined at least partially between compression mechanism <NUM> and <NUM> within the pinch area <NUM>. The compression mechanism <NUM> and/or the compression mechanism <NUM> forms a path from point A to point B of the pinch zone and at least a portion of this path allows for cooling the newly formed longitudinal seal <NUM> on the flexible material <NUM> while still under pressure from the compression mechanisms within the pinch area <NUM>. The longitudinal seal <NUM> is formed by a heating assembly <NUM> that is a part of sealing assembly <NUM>.

The peripheral area the curved surface 162a along the compression mechanism <NUM> forms a contact area that engages the flexible material directly. As discussed in more detail below, in some embodiments, the peripheral area is cylindrical and accordingly the peripheral area is the outer circumferential area of the cylinder. In other embodiments, the peripheral area is the outer area of the surface of the shape defining the compression mechanism <NUM>. Absent the holding pressure caused by the pinch area <NUM> against the cooling zone, the effectiveness of the longitudinal seal <NUM> would be reduced due to the air pressure within the inflated chamber. In accordance with various embodiments, the cooling zone is sufficiently long to allow sufficient cooling of the longitudinal seal <NUM> to set in the seal such that the air pressure within the inflated chamber <NUM> does not stretch or deform the longitudinal seal <NUM> beyond the longitudinal seal's <NUM> ability to hold the air pressure therein. If the cooling zone is not sufficiently long such the longitudinal seal does not properly set.

The pinch area can have any suitable shape. For example, the pinch area may be substantially rectilinear (e.g. <NUM>' in <FIG>). In a preferred example, the pinch area <NUM> is arcuate. Regardless of the shape, the pinch area can be made up of rollers, belts, or other suitable drive mechanisms. As shown in the <FIG>, the pinch zone is defined by a combination of belts and disks.

If the pinch zone is arcuate, and the angle between the pinch points A and B is too large, the inflated material could wrap back on itself. Thus the location of the pinch point A and B relative to one another around the curved surface path 162a is preferably one that produces the best seal without allowing the flexible material to interfere with itself thereby providing a superior with longitudinal seals <NUM> that adequately hold the air. In accordance with various embodiments, the pinch point A is located at an angle that is greater than <NUM>° from the pinch point B as measured around axis 161a. In accordance with various embodiments, the pinch point A is located at an angle that is less than <NUM> from the pinch point B as measured around axis 161a. In accordance with various embodiments, the pinch point A is located at an angle that is between than <NUM>° and <NUM>° from the pinch point B as measured around axis 161a. In accordance with various embodiments, the pinch point A is located at an angle that is between than <NUM>° and <NUM>° from the pinch point B as measured around axis 161a. In accordance with various embodiments, the pinch point A is located at an angle that is about <NUM>° from the pinch point B as measured around axis 161a. In each of the above embodiments and examples, it should be appreciated that the pinch points A and B are defined by the positions and/or shapes of the compression mechanisms <NUM> and <NUM> relative to each other.

In accordance with various embodiments, the compression mechanisms can include adjustment mechanisms, biasing mechanisms or other suitable devices for controller their relationship between one another or the pressures between one another.

In accordance with a preferred embodiment, the drive mechanism <NUM> comprises opposing drive systems. In various examples, the opposing drive systems form part of or all of the compression mechanisms <NUM> and <NUM>. In various examples, as illustrated in <FIG>, one portion of the drive mechanism can include a driven belt <NUM>. In various examples, one portion of the drive mechanism can include a transport belt <NUM>. The transport belt may be driven or alternatively may be a passive idler feature driven merely by the web material <NUM> or another driven feature of the system. One portion of the drive mechanism can include a secondary surface <NUM> corresponding to one belt surface. One portion of the drive mechanism can include a guide surface <NUM> corresponding to another belt surface, roller surface, or stationary surface.

In accordance with various embodiments, the drive mechanism <NUM> includes the compression mechanism <NUM>. The compression mechanism <NUM> includes driven belt <NUM>. In some embodiments, belt <NUM> can define a portion of the web <NUM> path that is flat/rectilinear. In other embodiments, the belt <NUM> defines a portion of the web <NUM> path that is arcuate. The belt <NUM> pulls or pushes or otherwise transports the web <NUM> through the pinch area <NUM> and holds the web <NUM> sufficiently tight along the path of the pinch area <NUM> (either flat or arcuate) to retain the fluid within the chamber <NUM> as the longitudinal seal <NUM> is applied and then cools. Holding the longitudinal seal <NUM> tightly closed in the cooling zone <NUM> via belt <NUM> limits the stretching and deformation against the seal <NUM> caused by the air pressure within the inflated chamber <NUM>.

The drive mechanism <NUM> may drive the web <NUM> adjacent to the heating assembly <NUM> such that the heat seal <NUM> is continuously created as the web <NUM> is driven in a downstream direction. In one example, the drive mechanism <NUM> may tension the web <NUM> against the heating assembly <NUM>, via one or more compression elements, to create the longitudinal seal <NUM>. More particularly, the belt <NUM> may be tensioned, as described below, to create a compression force pinching at least a portion of the web <NUM> against the heating assembly <NUM>.

In accordance with various embodiments, the belt <NUM>, which may be referred to as an elastic belt, a first belt, or a second belt, includes many configurations. For example, the belt <NUM> may include a composition suitable for transporting the web <NUM> through the pinch area <NUM>. The belt <NUM> can have a high grip surface, such as a high tackiness and/or friction material on a surface of the belt <NUM> (e.g., a tacky exterior surface). The high grip surface of the belt <NUM> may be defined as part of the belt <NUM> itself, such as integrally formed with the belt <NUM>. The high grip surface of the belt <NUM> may be resultant from the properties of the material from which the belt <NUM> is formed. In some examples, the high grip surface of the belt <NUM> may be achieved by application of a substance or material onto the belt <NUM>. For instance, a tacky substance or material may be coated, sprayed, or otherwise applied to the belt <NUM>. In some examples, material may be coated, sprayed, or otherwise applied to the belt <NUM> to increase the friction between the belt <NUM> and the web <NUM>. In some examples, the high grip surface may be achieved by selective heating of at least a portion of the belt <NUM>. For example, the belt <NUM> may be formed from a material such that heating of the belt increases the tackiness and/or friction of the belt <NUM>. As described herein, a tacky material is one that is somewhat sticky, grippy, or grabby such that the belt <NUM> grips the web <NUM> with a relatively small force against the web <NUM>.

The belt can include an outer portion and an inner portion. The inner portion can include a reinforcement core, such as a Kevlar core. The core of the belt <NUM> may provide a desired structural characteristic. For example, the core may limit flexing or stretching of the belt, whether radially, longitudinally, or transversely, during operation. The belt <NUM> may be wider than the heating assembly <NUM>. The belt <NUM> may include a main surface, a bottom surface opposing the main surface, and a pair of opposing side surfaces extending between the main surface and the bottom surface. The belt <NUM> may bias the web <NUM> towards the heating assembly <NUM>. For example, the web <NUM> may be positioned between the belt <NUM> and the heating assembly <NUM> such that the belt <NUM> pinches at least a portion of the web <NUM> against the heating assembly <NUM>. In one example, the belt <NUM> may be positioned such that the main surface pinches the web <NUM> against the heating assembly <NUM>.

In one example, the outer portion of the belt <NUM> may facilitate transporting the web <NUM> through the pinch area <NUM>. For instance, the outer portion of the belt <NUM> may include a high grip characteristic. For instance, the belt <NUM> may include a high tackiness and/or a high friction material on a surface thereof that contacts the web <NUM> to grip the web <NUM> during heating by the heating assembly <NUM>. Without the high grip characteristic of the belt <NUM>, the web <NUM> may move (e.g., slip or slide) relative to the belt <NUM> without the belt <NUM> being significantly tensioned against the web <NUM>. The tackiness and/or friction characteristic of the belt <NUM> may facilitate the belt <NUM> gripping or grabbing the web <NUM> with less compressive force against the web <NUM>. As such, the tension of the belt <NUM> needed to drive the web <NUM> in a downstream direction through the pinch area <NUM> may be significantly reduced due to the high tackiness and/or friction characteristic of the belt <NUM>. In one example, the effective compression force of the belt <NUM> through the pinch area <NUM> may be between a minimum of around <NUM>, <NUM>, or <NUM> (<NUM> lb. , <NUM> lb. , or <NUM> lb. ) and a maximum of around <NUM>, <NUM>, or <NUM> (<NUM> lb. , <NUM> lb. , or <NUM> lb. ), such as between around <NUM> and <NUM> (<NUM> lb. and <NUM> lb. In some designs not utilizing a high tackiness and/or a high friction belt, the effective compression force through the pinch area can be significantly higher, such as between two to four times higher.

The high grip characteristic of the belt <NUM> may be defined by a material of the belt <NUM>. For example, the belt <NUM> may be formed at least partially from an elastomeric material. In one example, the tacky exterior surface is defined by an elastomeric material. In one example, the outer portion of the belt <NUM> may be formed at least partially from an elastomeric material. The elastomeric material may be a synthetic material, a natural material, or a combination of synthetic and natural materials. Depending on the particular application, the elastomeric material may be a saturated rubber, such as silicone, EPM, and/or EPDM rubber. The elastomeric material may be an unsaturated rubber, such as natural, butyl, styrene-butadiene, and/or nitrile rubber. The elastomeric material may be a thermoplastic elastomer, a thermoplastic polyurethane, a thermoplastic olefin, and/or a thermoplastic vulcanizate. In one example, the belt <NUM> may be formed at least partially from a low durometer rubber or silicone. In some examples, the belt <NUM> may be textured and/or shaped to include a high grip surface. For example, the belt <NUM> may include a high surface roughness. In some examples, the belt <NUM> may be ribbed or otherwise configured to increase friction between the belt <NUM> and the web <NUM>.

In some examples, the belt <NUM> may be resiliently or elastically stretchable. For example, the belt <NUM> may be formed at least partially from generally elastic material, such as rubber or silicone. In such examples, the belt <NUM> may stretch or elastically deform around adjacent structure in driving the web <NUM> through the pinch area <NUM>, as explained below. The stretchable characteristic of the belt <NUM> may be in conjunction with or as an alternative to the high grip characteristic described above. More particularly, the belt <NUM> may include a high grip characteristic, a stretchable characteristic, or a high grip and stretchable characteristic.

The belt <NUM> may be configured as described above, whether in conjunction with belt <NUM> or not. For example, the belt <NUM>, which may be referred to as a first belt or a second belt, may have a high tackiness characteristic, such as being formed from a high tackiness material. In this manner, either the belt <NUM>, the belt <NUM>, or both the belt <NUM> and the belt <NUM> may have a configuration suitable for transporting the web <NUM> through the pinch area <NUM>. As described more fully below, the web <NUM> may be positioned between the belt <NUM> and the belt <NUM>. In such examples, the drive mechanism <NUM> may include a high tackiness belt on either side of the web <NUM> to facilitate movement of the web <NUM> through the pinch area <NUM> with a lower effective compression force therethrough. In some examples, the belt <NUM> may be formed from a material different than the belt <NUM>. For instance, the belt <NUM> may be less tacky than the belt <NUM>. In one example, the belt <NUM> is formed at least partially from polytetrafluoroethylene, or other similar material.

In accordance with various embodiments, as illustrated in <FIG>, belts <NUM> and <NUM> oppose one another. Belts <NUM> and <NUM> are configured relative within the pinch area <NUM> and receive the web <NUM> therein. More specifically, in the embodiments shown, the belt <NUM> compresses against the web-support surface <NUM> defining the pinch zone, which overlaps longitudinally with the heating zone <NUM>. In various embodiments, the pinch zone <NUM> includes a plurality of pressure regions transverse to one another. For example, the pinch zone <NUM> can include a first region 276a and a second region 276b. In some embodiments, the plurality of pressure regions can apply different forces on the web material <NUM>. In other embodiments, the pressure regions apply similar forces in different manners. In one example, a compression element (e.g. belt <NUM>) presses against two different opposing pressure elements (e.g. disc <NUM> and heater assembly <NUM>). In this way the opposing pressure elements can apply pressure to the compression element in different ways creating two different pressure regions (e.g. the first pressure region 276a and the second pressure region 276b). In instances of different pressure forces in these regions the compression element (e.g. belt <NUM>) can deflect or deform to accommodate the different pressures. The deflection distance D. can be from about <NUM>. <NUM> to <NUM> (<NUM> mils to <NUM> mils). The outer pressure can be considered an isolation pressure as it is able to aid in isolating the fluid in the air chambers <NUM>. In embodiments where the forces are different in each of the regions 276a and 276b, the differences can be caused for example, by a narrower region to pass the web material through with respect to the other region. In another example, the region sizes are similar but the opposing compression elements have different materials. As such, the web material will deflect one material more and as a result one material will apply a higher pressure than the other. In other embodiments, the different regions merely have pressure coming from different directions, or locations, or as illustrated in the example of <FIG> the isolation element <NUM> actually extends into the compression element (e.g. belt <NUM>) whereas the support structure <NUM> does not. In a preferred embodiment, the isolation element <NUM> is a continuous surface that substantially matches the profile of the device forming the adjacent region. For example, the support surface <NUM> is curved similarly to the isolation surface <NUM>. In other embodiments, the isolation element <NUM> has a discontinuous surface <NUM>. For example, the isolation element <NUM> can be a wheel that has fingers that contact the martial and sufficient intervals to limit fluid passage or otherwise stabilize the web material <NUM>.

In accordance with various embodiments, the isolation element <NUM> is configured to block or resist the flow of fluid from the inflatable chambers <NUM> back toward the nozzle. Additionally or alternatively, the isolation element <NUM> is configured to isolate the portion of the web material <NUM> that is being sealed from the movement of the portion of the web material <NUM> that extends transversely from the system. Either one or both of these results can be accomplished by an increased pressure applied to the web martial transversely of the sealing region, or by applying a complex bend or curve to the web material <NUM> as it passes through the sealing mechanism. In accordance with various embodiments, the isolation element <NUM> can remain in contact with the web material <NUM> through both the cooling and heating zones of the sealing mechanism. As discussed herein, the isolation element <NUM> and/or the surface <NUM> is transversely offset from support structure <NUM> or other compression mechanism used to define the pinch zone. Preferably, the isolation element <NUM> and the support structure <NUM> are longitudinally aligned. The transverse offset is sufficiently small to allow the isolation element <NUM> to bock or resist the flow of fluid between the chambers <NUM> and the nozzle. In one example, the offset G (see <FIG>) is less than the thickness of the belt <NUM>. In another example, the offset is less than ½ the thickness of the isolation elements transverse thickness.

In accordance with one example as shown in <FIG>, the compression mechanism <NUM> includes an isolation element <NUM> having a surface, <NUM>. For example, the belt <NUM> may bias the web <NUM> against the isolation surface <NUM> of the isolation element <NUM>. In such examples, the web <NUM> may be biased against the secondary surface <NUM> to seal the fluid within the chamber <NUM> as the longitudinal seal <NUM> is created. As described below, the isolation element <NUM> may deflect a portion of the belt <NUM> in a direction generally normal to the main surface of the belt <NUM>, such as upwardly or downwardly. In such examples, the belt <NUM> may flex to accommodate the deflection caused by the isolation element <NUM>. For instance, the belt <NUM> may flex radially to accommodate the deflection of the isolation element <NUM>.

The isolation surface <NUM>, which may be referred to as an isolation surface or a second sealing surface or secondary surface, may be adjacent to the guide surface <NUM>. In one example, the secondary surface <NUM> can be generally aligned with the surface <NUM> in the longitudinal direction L. In accordance with various embodiments, the isolation surface <NUM> is located in front of, behind, or both in the transverse direction relative to the surface <NUM>.

The secondary surface <NUM> may be stationary, flat or rectilinear, arcuate, or any combination thereof. In some embodiments, the isolation element <NUM> may be rotating disc. Preferably, the belt <NUM> and the isolation surface <NUM> are offset longitudinally from one another. However, in alternative embodiments, they can overlap as well with the belt <NUM> extending under the isolation surface <NUM>. The isolation surface <NUM> and the support surface <NUM> do not necessarily contact the opposing compression mechanism at the same level. Alternatively, the isolation surface <NUM> and the support surface <NUM> can have perpendicular offsets relative to one another allowing on or the other to extend farther into or towards the opposing compression mechanism (e.g. belt <NUM>). As used herein the perpendicular direction of the offset is the direction perpendicular to the major surface of the web material as it moves through the system. Even when accounting for intermediate components (e.g. belt <NUM>, heating element <NUM>, low friction intermediary <NUM>, etc., discussed in more detail below), the isolation surface <NUM> can extend farther into or towards the belt <NUM> than surface <NUM> with the intermediate components defining a disk pressure offset D. <FIG> illustrates the disk pressure offset D. The disk pressure offset D. is about <NUM> (<NUM> inches). In some embodiments, the surface <NUM> is stationary. In some examples, the surface offset D. may be equal to the material thickness of the web <NUM>, greater than the material thickness of the web <NUM>, or less than the material thickness of the web <NUM>. In these and other examples, the belt <NUM> may flex radially to accommodate the surface offset D. between the surfaces <NUM> and <NUM>. In embodiments where the belt <NUM> is resiliently or elastically stretchable, the belt <NUM> may resiliently or elastically stretch to conform to the surfaces <NUM> and <NUM>. For instance, the belt <NUM> may deform elastically around the surfaces <NUM> and <NUM> to accommodate the surface offset D. between the surfaces <NUM>, <NUM>. In such examples, the belt <NUM> may resiliently stretch in a direction normal to the main surface of the belt <NUM> to accommodate the surface offset D.

The belt <NUM> may create respective compression forces pinching at least portions of the web <NUM> against the surfaces <NUM> and <NUM>. In such examples, the compression forces of the belt <NUM> at the surfaces <NUM> and <NUM> may be different. For instance, the compression force of the belt <NUM> against the surface <NUM> may be lower than the compression force of the belt <NUM> against the surface <NUM>. In such examples, the surface offset D. may create the different compression forces of the belt <NUM> against the surfaces <NUM> and <NUM>. The compression forces may be sufficient to achieve a desired functional characteristic. For example, the compression forces may be low but sufficient to permit the belt <NUM> to drive the web <NUM> through the pinch area <NUM>. Additionally, the compression force of the belt <NUM> against the surface <NUM> may be sufficient to limit air leakage from the chamber <NUM> while the seal <NUM> is created adjacent to surface <NUM>. More particularly, the compression force of the belt <NUM> against the surface <NUM> may be sufficient to substantially isolate the pressure inside the chamber <NUM> from the heat seal area adjacent to surface <NUM>.

In other embodiments, the surface <NUM> forms a part of a rotating disc <NUM>. In such embodiments, as the web material moves through the sealing assembly, the web material rotates the disc. In other embodiments, the drive system rotates the disc.

<FIG> and <FIG> illustrate an alternate embodiment having a flat pinch zone <NUM>', in the embodiment upper (164a/b) and lower (e.g. 163a/b) compression element apply pressure to the web material <NUM> at different levels deflecting the material laterally. For example, belts 163a and 163b are offset in in the perpendicular direction relative to one another a distance of D. The pressures are offset relative to one another a distance of D. P due to the different opposing compression elements applying pressure at different levels. In this way a linear pinch zone <NUM>' also establishes different pressure regions 276a' and regions 276b'. Internal structures such and support 163c and/or heating assembly <NUM>' can also be position or biased to provide or resist pressure from the other elements.

<FIG> illustrate an alternate embodiment having a flat pinch zone <NUM>", in the embodiment the upper (164a/b") and the lower single (e.g. 163d") compression element apply pressure to the web material <NUM> at different levels deflecting the material laterally and the lower compression element laterally. The opposing compression elements 164a" or 164b" with 163d" form the opposing pressure causing the offset D. In this way a linear pinch zone <NUM>" also establishes different pressure regions 276a" and regions 276b". This is shown as an example with a single lower belt that is also deflected D. The deflection can help isolate fluid out of the nozzle and away from the forming seal.

In accordance with various embodiments, the drive mechanism <NUM> includes the compression mechanism <NUM>. The compression mechanism <NUM> can include belt <NUM>. In accordance with various embodiments, the compression mechanism <NUM> includes guide surface <NUM>. In accordance with various embodiments, the guide surface <NUM>, which may be adjacent to the heating assembly <NUM> and which may be referred to as a first sealing surface, may set at least a portion of the belt path of the belt <NUM> and/or the belt <NUM>. For example, the belt <NUM> and/or the belt <NUM> may wrap around the guide surface <NUM>. In some examples, the guide surface <NUM> may protrude into a line between adjacent belt supports to form a bent belt path. In some embodiments, the guide surface may be movable, e.g. being the surface around an idler or drive pulley. As illustrated in <FIG>, the guide surface <NUM> is stationary. As seen from a side view of the drive mechanism (i.e. transversely across the web), the guide surface can be flat/rectilinear (see e.g. <FIG> and <FIG>) or the guide surface can be arcuate (see e.g. <FIG>). In one example, as illustrated in <FIG> the guide surface is arcuate and sets at least a portion of the path of the drive mechanism (e.g. belt <NUM>) in an arc as shown by example in <FIG>. Additionally or alternatively, the drive mechanism (e.g. belts <NUM> and <NUM>) forms a part of the compression mechanism and pulls against or otherwise places a compressive pressure against an opposing surface (e.g. the web-support surface <NUM>), where one or more of the compression mechanisms are sufficiently stationary to provide an opposing force. In this manner the opposing surface (e.g. web support surface <NUM>) defines a portion of the path for both belts <NUM> and <NUM>. This portion of the path is the pinch area <NUM>. In such examples, belts <NUM> and <NUM> may be biased against the guide surface <NUM> to pinch the plies of web <NUM> together. In a preferred embodiment, the guide surface <NUM> is at least partially circular and/or circular through the pinch zone <NUM>.

To elaborate on the particular example shown in <FIG>, the drive mechanism <NUM> can include a compression belt <NUM> and a transport belt <NUM>. The compression belt <NUM> wraps around a drive pulley (e.g. <NUM>) and one or more idler pulleys (e.g. <NUM>). Any of the pulleys can include a tensioning mechanism for locating or tensioning the compression belt <NUM>. The drive mechanism <NUM> may also include an idler pulley (e.g. <NUM>) position to wrap the compression belt around an opposing compression element. As shown in this example the opposing compression element is the heating assembly <NUM>. The heating assembly <NUM> includes the support structure <NUM> which defines the support surface <NUM>. The pulleys are positioned to cause the compression belt <NUM> to wrap around and exert a pressure on the support surface <NUM>. This interaction defines the pinch zone <NUM>. The drive mechanism can also include a transport belt <NUM> which is also wrapped around the support surface <NUM>. Pulleys <NUM> can support, guide, and position the transport belt around the support surface <NUM>. Any of the pulleys can include a tensioning mechanism for locating or tensioning the transport belt <NUM>.

In accordance with various embodiments, the transport belt can be a low friction material especially in comparison to the compression belt <NUM>. In a preferred embodiment, the transport belt <NUM> is a Teflon belt. In a preferred embodiment, the transport belt is about <NUM>-<NUM> (<NUM>-<NUM> mils) thick.

Of note, and to reiterate the description above, the drive mechanism can be any suitable system including belts, rollers, or other suitable transportation devices. The embodiments illustrated in <FIG> and described herein, are merely examples of one type of suitable system, the system using opposing belts that and a pressure disc. A person of ordinary skill in the art will understand in light of the disclosure herein that the concepts discussed with respect to the belts or the disks may be applied to other systems utilizing rollers or other web transportation devices.

In accordance with various embodiments, the inflation and sealing device <NUM> may include one or more covers (e.g. <NUM> and <NUM>) over the inflation and sealing assembly <NUM>. The covers (e.g. <NUM> and <NUM>) can be operable to redirect the web after the web exits the pinch area <NUM> at point B. For example, the covers include a deflection surfaces 182a and/or 184a that contacts the flexible material <NUM> as it exists at point B and aids in separating the flexible material <NUM> from the compression mechanisms <NUM> and <NUM> redirecting the web material <NUM> in any desired direction. The cover may be a harder material than the rollers and sufficiently smooth and continuous to have relatively little engagement or adhering tendency with the web material <NUM>.

In each of these various systems for drive mechanisms referred to above, the sealing assembly <NUM> also includes a heating assembly <NUM> operable to seal the different layers of the web material <NUM> to one another.

In accordance with a preferred embodiment, the heating assembly <NUM> is stationary. Examples of various heating assemblies and heating elements positioned stationary while the flexible material <NUM> and the drive mechanisms move relative to the heating assemblies and heating elements are depicted in <FIG>. By positioning the heating assembly <NUM> so that the heating assembly <NUM> remains stationary while the flexible web material <NUM> moves across the heating assembly <NUM>, the entire seal is formed by the same section of heating assembly allowing for greater consistency in heating assembly temperature, positioning, and overall conditions, which in turn provides for consistent seals. The stationary position of the heating assembly <NUM> also allows for simplified construction of certain heating elements and or heating element tensioning mechanisms, which further improves the consistent application of the seals.

In accordance with various embodiments, the heating assembly <NUM> can define at least a portion of the path E. In more particular embodiments, the heating assembly <NUM> can define a portion the pinch zone <NUM> along path E. As discussed above, this portion of the path E can be rectilinear or curved. <FIG> illustrates an example of a rectilinear path. Whereas the <FIG> illustrate an example of a curvilinear path. In either embodiment, the heating assembly <NUM> can support the heating element <NUM>. This may be done directly or indirectly. For example, a belt mounted over the heating assembly <NUM> may be used to direct heat to the web-material <NUM>. In other examples, a separate heating element <NUM> may be mounted directly to the heating support structure <NUM>. In such an example, other covers shield, belts, or suitable protective devices can separate the heating element <NUM> from the web-material <NUM>. For example, protection element <NUM> can cover the heating element <NUM> protecting it from the transport belt or other moving feature of the system (e.g. film, compression element, roller, etc.).

In one example, the heating assembly <NUM> is attached to or otherwise extends from the cover <NUM>. As discussed above, the heating assembly <NUM> is positioned adjacent to one or more drive members and relative to the compression mechanism <NUM> or <NUM>. In a more particular example, the heating assembly, when viewed from the side as shown in <FIG>, the heating assembly is mounted and defines surface <NUM> that sets at least a portion of the curvature of belts <NUM> and <NUM>. In accordance with various embodiments, the heating assembly <NUM> includes a first conductive support <NUM>, a second conductive support <NUM>, an insulative support <NUM>, and a heating element <NUM>. The first conductive support <NUM>, second conductive support <NUM>, insulative support406 are connected together and define the web-support surface <NUM>. In various examples, the heating element <NUM> is oriented along surface <NUM>. Preferably, the heating element is longitudinally straight with both narrow and wide portions receiving pressure in the pinch zone <NUM>.

In accordance with various embodiments, the heating element <NUM> is electrically connected to both conductive supports <NUM>/<NUM>. The heating element is laid across and supported by the conductive and insulative support <NUM>. The portion of the heating element <NUM> that is laid across and supported by the conductive and insulative support <NUM> defines, at least in part, a portion or all of the heating zone <NUM>. In this embodiment, the insulative support <NUM> electrically separates the conductive supports <NUM>/<NUM>. Alternatively or additionally the insulative support <NUM> can be thermally insulating. With thermally insulating properties, the insulative support <NUM> can help control the temperature differential between the cooling zones and the heating zones, thereby improving the seal quality and/or efficiency.

In accordance with various embodiments discussed herein, the heating element <NUM> may include a high heat region <NUM> that has relatively high temperature compared to the remaining extent of the heating element <NUM>. The heat zone <NUM> of heating element <NUM> corresponds to the heating zone <NUM>. The high heat region <NUM> is offset to the upstream end of the surface <NUM>. The upstream end of the web-support surface <NUM> also corresponds to the upstream end of the pinch zone <NUM>. By offsetting the heating zone <NUM> to the upstream end of the pinch zone <NUM>, the pinch zone <NUM> can be utilized to apply pressure to the web material <NUM> during both the heating portion of the process and the initial cooling process. In some embodiments, the heating element <NUM> can have different sections of different heat levels that extend throughout various regions along the material path of the pinch zone <NUM>. In this way, the temperature of the web material <NUM> can be controlled after the seal is formed in the heating zone <NUM>, while still applying pressure via the pinch zone <NUM>.

In accordance with various embodiments, the heating element <NUM> extends the entire length of the pinch zone <NUM>. Preferably, the heating element <NUM> is longer than the pinch zone <NUM> but in some examples can be shorter. Within the pinch zone <NUM> there is a heating zone <NUM> and a cooling zone <NUM> after the heating zone. In various examples, the heat zone is between about ¼ and ½ the length of the heating element. Preferably the heat zone is about ¼ the length of the heating element. In various examples, heat zone is between about ½ and ¾ the length of the pinch zone. Preferably, the heat zone is about <NUM>/<NUM> the length of the pinch zone. The cooling zone is between about <NUM>/<NUM> and <NUM>/<NUM> the length of the pinch zone. Preferably, the cooling zone is about <NUM>/<NUM> the length of the pinch zone <NUM>.

In various embodiments, the heating assembly <NUM> is positioned transversely between the nozzle <NUM> and the chambers <NUM> being inflated to seal across each of the transverse seals. Some embodiment can have a central inflation channel, in which case a second sealing assembly and inflation outlet may be provided on the opposite side of the nozzle. Other known placement of the web and lateral positioning of the inflation nozzle and sealing assembly can also be used.

After inflation, the web material <NUM> is advanced along the material path "E" towards the pinch area <NUM> where it enters the sealing assembly <NUM>. In one example, the pinch area <NUM> is disposed between adjacent compression mechanisms <NUM> and <NUM>. The pinch area <NUM> is the region in which the first and second plies <NUM>,<NUM> are pressed together or pinched to prevent fluid from escaping the chambers <NUM> and to facilitate sealing by the heating assembly <NUM>. As illustrated in <FIG>, the pinch area <NUM> may include a pinch region between the compression mechanism <NUM> and the heating assembly <NUM>. The pressure produced in this pinch area between compression mechanism <NUM> and the heating assembly <NUM> helps form the seal. As indicated above, the heating assembly <NUM> can be stationary. Thus, in such embodiments, the pinch area <NUM> between the compression mechanism <NUM> and the heating assembly <NUM> includes a moving element, e.g. the compression mechanism <NUM> and a substantially stationary element, e.g. heating assembly <NUM>. In accordance with various embodiments, the drive mechanism <NUM> rollers <NUM> and <NUM> can be compressed against one another for driving the flexible material <NUM> through the system and the rollers <NUM> and <NUM> can open for threading the flexible material <NUM> over the drive mechanism <NUM>. Similarly, the open state of the drive mechanism <NUM> also allows threading the flexible material <NUM> between the heating sealing assembly <NUM> and the opposing roller <NUM> as shown in <FIG>.

The heating assembly <NUM> includes a heating element <NUM> disposed adjacent to the pinch location to heat the pinch area <NUM>. While in the various embodiments disclosed herein the compression mechanisms adjacent to the pinch area <NUM> can roll, the heating element assembly <NUM> is a stationary heating element. As indicated above, the pinch area <NUM> is the area where the compression mechanisms <NUM> and <NUM> are in contact with each other or with the web material <NUM> and similarly compression mechanism <NUM> and heating element assembly <NUM> are in contact with each other or with the flexible material <NUM>.

As discussed above, the heating assembly <NUM> includes one or more heating elements <NUM>. The heating elements can be any material or design suitable to seal together adjacent plies together. In various embodiments the heating elements <NUM> can be resistive foil. The foil can be formed of nichrome, iron-chromium-aluminium, cupronickel or other metals suitable for forming and operating a heating element under conditions that are used for sealing plies of the flexible material together allowing the heating element <NUM> to melt, fuse, join, bind, or unite together the two plies <NUM>,<NUM>. In a preferred embodiment, the heating element <NUM> is formed from about <NUM>% nickel and <NUM>% chromium annealed soft. In other embodiments, the heating element <NUM> can be a thin film heater element. The thin film heating element <NUM> can be formed of barium titanate and lead titanate composites or other materials suitable for forming and operating the heating element under conditions that allow the heating element <NUM> to obtain a sufficient heat to seal the plies together. In accordance with various embodiments, the heating element <NUM> heats up to between about <NUM>° to <NUM>° C (<NUM>° to <NUM>° F). Preferably the heating element <NUM> reaches about <NUM>° C (<NUM>° F). The ends of the heating element reach a lower heat of between about <NUM>° to <NUM>° C (<NUM>° to <NUM>° F). Preferably the ends reach about <NUM>° C (<NUM>° F).

In accordance with various embodiments, as illustrated in <FIG>, the heating element includes a high heat portion <NUM> and a low heat portion <NUM>. The high heat portion <NUM> is defined by a portion of the heating element's <NUM> length with a reduced cross-section. The reduced cross-section increases the resistance in the heating element. The increased resistance causes the heating element <NUM> to significantly increase in temperature across the high heat portion <NUM> that is sufficient to heat the plies to create the longitudinal seal that seals the first and second plies of film together. The low heat portion <NUM> is defined by regions of the heating element that have a larger cross-section than the low heat portion. The larger cross-sections have a lower resistance in response to an applied current resulting in a lower temperature of the low heat portion <NUM>. In various embodiments, the low heat portion is significantly above ambient temperature of the sealing device. In various embodiments, the high heat portion <NUM> is located closer to one end of the heating element <NUM> than the other end of the heating element <NUM>. This offset position allows the high heat portion <NUM> to be offset on the upstream end of the pinch zone discussed above.

In accordance with an example of the heating element <NUM>, the heating element <NUM> is about <NUM> to <NUM> (<NUM> to <NUM>½ inches). The heating element <NUM> includes a first low heat portion <NUM> having a length L3 of between <NUM> to <NUM> (<NUM>¼ to <NUM><NUM>/<NUM> inches) The heating element <NUM> includes a second low heat portion <NUM> having a length L1 of between about <NUM> to <NUM> (<NUM>¾ to <NUM><NUM>/<NUM> inches) The low heat portions are about <NUM> to <NUM> (¼ to <NUM>/<NUM> inches) wide. The low heat portions are connected at a high heat portion <NUM> with a length L2 of between about <NUM> and <NUM> (<NUM>½ and <NUM> inches). The element is about <NUM> (<NUM>/<NUM> of an inch) wide. The heating element <NUM> may be from about <NUM> - <NUM> (<NUM>-<NUM> mils) thick and preferably about <NUM> (<NUM> mils) thick. In response to a current being applied across the heating element <NUM>, the low heat portion heats up to about <NUM>° C (<NUM>° F) and the high heat portion heats up to about <NUM>° C (<NUM>° F).

In accordance with various embodiments, as illustrated in <FIG>, the heating element includes connection elements <NUM> and <NUM> one each end suitable to attach to the heating assembly <NUM>. In one example the connection elements are apertures operable to be connected to connection elements <NUM>/<NUM> on the heating support structure <NUM>.

In accordance with various embodiments, a low friction layer <NUM> is located between the stationary heating element <NUM> and the moving roller <NUM> or flexible material <NUM>. The low friction layer <NUM> is suitable to decrease the wear between the roller <NUM> and the heating element <NUM>. In embodiments having a heating element <NUM>, the low friction layer <NUM> decreases abrasion to the element and may also limit the tendency of the heating element <NUM> to cut into the flexible material <NUM> during sealing. In embodiments having a thin film heat element <NUM>, the low friction layer <NUM> decreases abrasion to the substrate supporting the heating element <NUM> and the heating element <NUM> itself. As the thin film heat element <NUM> tends to be structurally thinner than wire heating elements, the low friction layer <NUM> also limits the deterioration of the thin film heating element <NUM> due to abrasion. The low friction layer <NUM> also allows for smoother transition of the flexible material <NUM> across the heating element <NUM> improving the seal. In one example, the low friction layer is a thin strip of polytetrafluoroethylene (PTFE) attached across the exposed portion of the heating element <NUM>. Additionally by using the PTFE as a wear element, the layer can be replaced without replacing the more expensive heater element. The PTFE can be attached as a tape to the heating element and surrounding components. A nonadhesive layer of PTFE can also be mechanically positioned relative to the heating element. Mechanical fixturing allows the swapping out of parts without concern over the adhesive. For example, screw attachments or clips or other mechanical hardware to hold the PTFE in place or a housing can be molded to accommodate the layer. In other examples, other low fiction materials that can accommodate the heat created at the heating element <NUM> such as silicone are applied.

In accordance with one embodiment as illustrated in <FIG>, the heating element <NUM> is a NiChrome wire or foil. The heating element <NUM> includes the NiChrome wire <NUM> stretched across an insulator block <NUM>. Each side of the NiChrome wire <NUM> is attached to contacts <NUM> and <NUM>. Electrical leads <NUM> and <NUM> are connected to the contacts <NUM> and <NUM> such that current can be provided to the heating element <NUM> to cause it to heat up. By controlling the width of the wire the heat output is affected. For example, narrowing the wire width increases the heat output compared to the same electrical input. This has the drawback however of narrowing the seal formed on the flexible material. In some examples, the seal width is controlled by providing multiple traces of wire for the heating element.

In accordance with one embodiment as illustrated in <FIG>, the heating element <NUM> is a thin film heater. In such embodiments, the heating element assembly <NUM> includes a heating element <NUM> having a thin film heat trace that connects two contacts. The heating element <NUM> can be suspended by a substrate. For example, the heating element assembly includes a polyimide substrate that backs the heat trace. The heating element <NUM> can be sandwiched between two layers of substrate. The heating element <NUM> can formed by vapor deposition on a polyimide layer. In one example, the polyimide layers are between about <NUM> and <NUM> mils thick. In a preferred example, the polyimide layers are about <NUM> mils thick each. The polyimide layers sandwich the heat trace <NUM>, which in one example is between about <NUM> and <NUM> mils thick. In a preferred example, the heat trace <NUM> is about <NUM> mils thick. The polyimide layers encapsulate the heat trace and provide isolative properties. The process that binds the polyimide together handles the temperature that the heating element <NUM> is capable of creating, eliminating the need for adhesives. Typically the adhesives have a lower functional temperature and as such are generally avoided with heating elements. In addition one variable is eliminated from the assembly by bonding the polyimide directly to itself.

In other embodiments the heating element <NUM> circuit can be formed of layers of fluorinated ethylene propylene (FEP) on the heat trace <NUM>. In this structure high heat and high pressure negates a need to use an adhesive. Also the outer layer of FEP can be textured to decrease friction and sticking with other components. In other embodiments, the thin film circuit <NUM> can be subsequently wrapped in another material such as silicone providing additional protection, provides insulation, acts as a bonding agent and provides additional manufacturing options such as over-molding of the circuit.

The heating element <NUM> is held in tension across a backing block <NUM>. Each of the two contacts on the heating assembly <NUM> is connected to heating assembly contacts <NUM> and <NUM>, which in turn are connected to electrical leads <NUM> and <NUM>. In any of the heating assembly embodiments discussed herein, the heating element <NUM>, contacts <NUM>/<NUM>, and the insulator block may be positioned inside our outside of the structure of heating assembly <NUM>. The low friction layer <NUM> may also be applied along the surface <NUM>.

In various example, the housing of heating assembly <NUM> has an elongated "U" shape suitably sized to the belt path and web path through the pinch zone <NUM> alone surface <NUM> of the "U" shaped housing while the housing remains stationary. The housing can also include standoffs <NUM> and <NUM> suitable to align the housing <NUM> with the belts <NUM> and/or <NUM>. In one example, the standoffs attach to the plate <NUM> and space the housing away from the plate the proper distance to align the housing belts. The standoffs <NUM> and <NUM> also can house the electrical leads respectively. While it is discussed herein by way of example, that the heating assembly <NUM> aligns with a belt drive mechanism, it should be appreciated that other embodiments are also covered, such as alignment with the end of a roller or drum, or alignment with a belt drive mechanism, or any structural relationship that allows the flexible material to be conveyed past the stationary heating assembly. In another embodiment, the flexible material could be stationary and the heating assembly driven across the stationary flexible material.

In accordance with various embodiments, the heat sealer assembly <NUM> includes a tension mechanism for the heating element <NUM>. The tensioning mechanism is a system configured to hold tension in the heating element <NUM> across the backing block <NUM>. As the heating element heats up and cools down, the length and/or structure of the heating element changes. These changes can modify the relationship between the heating element <NUM> and the surrounding components or the flexible material <NUM>. In wire applications, the change in length of the wire heating element can be sufficiently large causing poor seals to form and potentially causing the wire heating element to cut the flexible material <NUM>. As the heating element due to increase in temperature the added length of the heating element is "absorbed" by the tension mechanism allowing the heating element to remain flush against the backing block and stay in position. When the heating element is not flush against the backing block, there is the potential of cutting the film as you seal. Constant pressure will provide a consistent seal. In various embodiments, one or more of the contacts <NUM> and <NUM> can be resilient thus providing a force to stretch the heating element across the backing block <NUM>. In one example, shown in <FIG>, the contact block <NUM> includes a lever and spring, placing the heating element <NUM> in tension. The spring <NUM> is suspended on a shelf in the housing of block <NUM> allowing the lever <NUM> to pivot away from the spring <NUM> placing the heating element <NUM> in tension. The spring tensioning mechanism also allows for changes in tension in the heating element during thermal expansion.

In another example, as shown in <FIG>, the tension mechanism can be built into the heating element assembly <NUM>. The thickness of the heat trace or physical pattern can be modified to provide various watt densities. The thin film element can have varying widths and lengths by changing the trace composition. The thin film element is also smoother decreasing or eliminating the likelihood of cutting the flexible material <NUM> with the heating element.

While the various embodiments and examples discussed herein are directed to a heating assembly <NUM> that is stationary, it should be appreciated that various features or elements of the various embodiments and examples discussed herein are applicable to some moving heating assemblies as well. In one example, the heating assembly <NUM> includes the disk <NUM>. Thus, some of the heating element assembly structures could move with the drive mechanism while others remain stationary. In another example, some of the heating element tensioning mechanisms could apply to moving heating assemblies. In other embodiments, the heating element assembly may move with the drive elements, be stationary relative to the moving drive elements, move relative to the movement of the compression mechanisms, move relative to the web material <NUM>, or be stationary relative to the housing <NUM>. Persons of ordinary skill in the art, based on the disclosure herein, can adapt these features and elements to a variety of other systems only some of which are disclosed herein in detail.

After being sealed, the first and second plies <NUM>,<NUM> are cooled under pressure along the cooling zone <NUM> allowing the seal to harden. The cooling zone <NUM> may act a heat sink or may provide a sufficient cooling time for the heat to dissipate into the air.

In the preferred embodiment, the heating assembly <NUM> and one or more of the compression mechanisms <NUM>, <NUM> cooperatively press or pinch the first and second plies <NUM>,<NUM> at the first pinch area <NUM> against the heating assembly <NUM> to seal the two plies together. The sealing assembly <NUM> may rely on pressure from compression mechanism <NUM> against the heating assembly <NUM> to sufficiently press or pinch the plies <NUM>,<NUM> there-between.

In accordance with various embodiments, the inflation and sealing assembly <NUM> may further include a cutting assembly <NUM> to cut the web material <NUM>. Preferably, the cutting member is sufficient to cut the web material <NUM> as it is moved past the edge along the material path "E". More particularly, the cutting assembly <NUM> may cut the first and second plies <NUM>, <NUM> between the first longitudinal edge <NUM> and mouth <NUM> of the chambers. In some configurations, the cutting assembly <NUM> may cut the web material <NUM> to open the inflation channel <NUM> of the web material <NUM> and remove the first and second plies <NUM>, <NUM> from the inflation nozzle <NUM>. In various embodiments, the inflation channel <NUM> of the flexible structure can be central to the structure or in other locations. In such embodiments, the cutting assembly <NUM> can still be adapted to remove the inflation channel <NUM> from the inflation and sealing assembly, particularly the nozzle <NUM>.

Claim 1:
A protective packaging formation device, comprising:
an inflation assembly (<NUM>) having a fluid conduit that directs fluid between first (<NUM>) and second (<NUM>) overlapping plies (<NUM>, <NUM>) of a web material (<NUM>);
a driving mechanism (<NUM>) that drives the web material (<NUM>) in a downstream direction through an arcuate pinch zone (<NUM>); and
a sealing mechanism (<NUM>) that includes a heating element (<NUM>) including a thin film heating element or a foil heater that includes a wide cross-section portion and a reduced cross-section portion, the size of the cross-sections selected such that the reduced cross-section portion produces high temperature zone that outputs sufficient heat to heat seal the plies to create a longitudinal seal (<NUM>) that seals the first (<NUM>) and second (<NUM>) plies together, trapping the fluid therebetween as the driving mechanism (<NUM>) drives the web material (<NUM>) past the heating element (<NUM>) in the downstream direction.