Apparatus for Inflating and Sealing Pillows in Packaging Cushions

Abstract

A machine which inflates and seals pillows in packaging is compact in overall size, can be conveniently operated to produce varied lengths of strips of inflated pillow-type packaging as needed, can begin production of inflated pillow-type strip packaging immediately after being held out of a production cycle for some period of time, and applies a heated sealing element directly to and in sliding contact with a web of film to securely seal the inlet port of an inflated pillow while the pillow is under pressure and as the web of film is continuously and uninterruptedly advanced through the machine.

1 . A system for manufacturing air cushions for use as packaging dunnage comprising: 
 (a) a longitudinally extending plastic film comprising a relatively narrow longitudinally extending channel, at least one row of generally rectangular presealed inflatable chambers each having an unsealed opening into the longitudinally extending channel, and a plurality of laterally extending perforations separating the inflatable chambers; and    (b) an inflation machine for inflating the inflatable chambers of the plastic film, the inflation machine comprising:    a pair of film drive rollers that cause the plastic film to be gripped at or near the narrow longitudinally extending channel and drawn in a continuous and uninterrupted manner through inflation, sealing and slitting mechanisms in a substantially planar path;    wherein the inflation mechanism comprises a source of inflation gas and an air outlet which together cause inflation gas to be injected into the relatively narrow longitudinally extending channel of the plastic film as the plastic film is drawn through the inflation mechanism;    wherein the sealing mechanism comprises an electrically energized heating element that generates heat to be delivered to the inflation side of one or more of the inflatable chambers to seal the unsealed opening and trap the inflation gas within the inflatable chambers as the plastic film is drawn through the sealing mechanism; and    wherein the slitting mechanism comprising a blade that slices open the relatively narrow longitudinally extending channel of the plastic film as the film is drawn through the slitting mechanism.    
     
     
         2 . The system of  claim 1  wherein the inflation mechanism comprises an elongate member adapted for insertion into the relatively narrow longitudinally extending channel of the plastic film as the film is drawn through the inflation mechanism; and 
 wherein the blade of the slitting mechanism slices open the relatively narrow longitudinally extending channel of the plastic film to allow the film to disengage from the elongate member as the film is drawn through the slitting mechanism.    
     
     
         3 . The system of  claim 2  wherein the elongate member has at least one opening for injecting inflation gas from the source of inflation gas into the narrow longitudinally extending channel of the plastic film.  
     
     
         4 . The system of  claim 1  wherein the inflatable chambers have a periphery defined by three closed sides and an inflation side having the unsealed opening, the inflatable chambers further comprising secondary heat seals within the periphery.  
     
     
         5 . The system of  claim 1  wherein the laterally extending perforations extend at least partway across the width of the film and separate each chamber or multiple chambers.  
     
     
         6 . The system of  claim 5  wherein the laterally extending perforations extend the entire width of the film.  
     
     
         7 . The system of  claim 1  wherein the source of inflation gas comprises a source of pressurized air.  
     
     
         8 . A system for manufacturing air cushions for use as packaging dunnage comprising: 
 (a) a longitudinally extending plastic film comprising a relatively narrow longitudinally extending channel and at least one row of generally rectangular presealed inflatable chambers each having an unsealed opening into the longitudinally extending channel; and    (b) an inflation machine for inflating the inflatable chambers of the plastic film, the inflation machine comprising:    an elongate member adapted for slidable insertion into the narrow longitudinally extending channel of the plastic film,    a pair of film drive rollers that cause the plastic film to be gripped at or near the narrow longitudinally extending channel and drawn in a continuous and uninterrupted manner through inflation, sealing and slitting mechanisms in a substantially planar path,    wherein the inflation mechanism comprises a source of inflation gas and an air outlet which together cause inflation gas to be injected into the inflation side of one or more of the inflatable chambers as the film is drawn through the inflation mechanism;    wherein the sealing mechanism comprises an electrically energized heating element that generates heat to be delivered to the inflation side of one or more of the inflatable air chambers to seal the unsealed opening and trap the inflation gas within the chambers as the film is drawn through the sealing mechanism; and    wherein the slitting mechanism comprising a blade that slices open the relatively narrow longitudinally extending channel of the plastic film to allow the film to disengage from the elongate member as the film is drawn through the slitting mechanism.    
     
     
         9 . The system of  claim 8  wherein the elongate member has at least one opening for injecting inflation gas from the source of inflation gas into the longitudinally extending channel of the plastic film.  
     
     
         10 . The system of  claim 8  wherein the plastic film further comprises a plurality of laterally extending perforations separating each chamber or multiple chambers.  
     
     
         11 . The system of  claim 10  wherein the laterally extending perforations extend the entire width of the film.  
     
     
         12 . The system of  claim 8  wherein the source of inflation gas comprises a source of pressurized air.  
     
     
         13 . Apparatus for inflating a plurality of inflatable chambers in a plastic film having a relatively narrow longitudinally extending channel to form inflated packaging pillows, the apparatus comprising: 
 a pair of film drive rollers that cause the plastic film to be gripped at or near the relatively narrow longitudinally extending channel and drawn in a continuous and uninterrupted manner through inflation, sealing and slitting mechanisms in a substantially planar path;    wherein the inflation mechanism comprises a source of inflation gas and an air outlet which together cause inflation gas to be injected into the inflatable chambers as the plastic film is drawn through the inflation mechanism;    wherein the sealing mechanism comprises an electrically energized heating element that generates heat to be delivered to seal an unsealed opening of the inflatable chambers and trap the inflation gas within the inflatable chambers as the plastic film is drawn through the sealing mechanism; and    wherein the slitting mechanism comprising a blade that slices open the relatively narrow longitudinally extending channel of the plastic film as the film is drawn through the slitting mechanism.    
     
     
         14 . The apparatus of  claim 13  wherein the air outlet injects air into the relatively narrow longitudinally extending channel.  
     
     
         15 . The apparatus of  claim 13  further comprising an elongate member adapted for insertion into the relatively narrow longitudinally extending channel of the plastic film; 
 wherein the blade of the slitting mechanism slices open the relatively narrow longitudinally extending channel of the plastic film to allow the film to disengage from the elongate member as the film is drawn through the slitting mechanism.    
     
     
         16 . The apparatus of  claim 13  further comprising an elongate member adapted for insertion into the relatively narrow longitudinally extending channel of the plastic film, wherein the elongate member has at least one opening for injecting inflation gas into the relatively narrow longitudinally extending channel of the plastic film.  
     
     
         17 . The apparatus of  claim 13  wherein the source of inflation gas is a source of pressurized air.  
     
     
         18 . Apparatus for use in inflating a plurality of inflatable chambers in a plastic film having a longitudinally extending channel, the apparatus comprising: 
 a driving mechanism configured to cause the plastic film to be gripped at or near the longitudinally extending channel and drawn in a continuous and uninterrupted manner in a generally planar path;    an inflation mechanism positioned along the generally planar path comprising a source of inflation gas and an air outlet which together are capable of injecting inflation gas into the inflatable chambers as the plastic film is drawn along the path and through the inflation mechanism;    a sealing mechanism positioned along the generally planar path comprising an electrically energized heating element capable of generating heat to be delivered to seal an unsealed opening of the inflatable chambers and trap the inflation gas within the inflatable chambers as the plastic film is drawn along the path and through the sealing mechanism; and    a slitting mechanism positioned along the generally planar path comprising a blade that is configured to slice open the longitudinally extending channel of the plastic film as the film is drawn along the path and through the slitting mechanism.    
     
     
         19 . The apparatus of  claim 18  wherein the air outlet is configured to inject air into the longitudinally extending channel.  
     
     
         20 . The apparatus of  claim 18  further comprising an elongate member adapted for insertion into the longitudinally extending channel of the plastic film; 
 wherein the blade of the slitting mechanism is configured to slice open the longitudinally extending channel of the plastic film to allow the film to disengage from the elongate member as the film is drawn along the path and through the slitting mechanism.    
     
     
         21 . The apparatus of  claim 18  further comprising an elongate member adapted for insertion into the longitudinally extending channel of the plastic film, wherein the elongate member has at least one opening capable of injecting inflation gas into the longitudinally extending channel of the plastic film.  
     
     
         22 . The apparatus of  claim 18  wherein the source of inflation gas is a source of pressurized air.  
     
     
         23 . The apparatus of  claim 18  wherein the driving mechanism comprises a pair of drive rollers.  
     
     
         24 . A system for manufacturing air cushions for use as packaging dunnage comprising: 
 (a) a longitudinally extending plastic film comprising a relatively narrow longitudinally extending channel, at least one row of generally rectangular presealed inflatable chambers each having an unsealed opening into the longitudinally extending channel, and a plurality of laterally extending perforations separating the inflatable chambers; and    (b) an inflation machine for inflating the inflatable chambers of the plastic film, the inflation machine comprising:    drive rollers that cause the plastic film to be gripped at or near the narrow longitudinally extending channel and drawn in a continuous and uninterrupted manner through inflation, sealing and slitting mechanisms in a substantially planar path;    wherein the inflation mechanism comprises a source of inflation gas and an air outlet which together cause inflation gas to be injected into the relatively narrow longitudinally extending channel of the plastic film as the plastic film is drawn through the inflation mechanism;    wherein the sealing mechanism comprises an electrically energized heating element that generates heat to be delivered to the inflation side of one or more of the inflatable chambers to seal the unsealed opening and trap the inflation gas within the inflatable chambers as the plastic film is drawn through the sealing mechanism; and    wherein the slitting mechanism comprising a blade that slices open the relatively narrow longitudinally extending channel of the plastic film as the film is drawn through the slitting mechanism.    
     
     
         25 . A system for manufacturing air cushions for use as packaging dunnage comprising: 
 (a) a longitudinally extending plastic film comprising a relatively narrow longitudinally extending channel and at least one row of generally rectangular presealed inflatable chambers each having an unsealed opening into the longitudinally extending channel; and    (b) an inflation machine for inflating the inflatable chambers of the plastic film, the inflation machine comprising:    an elongate member adapted for slidable insertion into the narrow longitudinally extending channel of the plastic film,    drive rollers that cause the plastic film to be gripped at or near the narrow longitudinally extending channel and drawn in a continuous and uninterrupted manner through inflation, sealing and slitting mechanisms in a substantially planar path,    wherein the inflation mechanism comprises a source of inflation gas and an air outlet which together cause inflation gas to be injected into the inflation side of one or more of the inflatable chambers as the film is drawn through the inflation mechanism;    wherein the sealing mechanism comprises an electrically energized heating element that generates heat to be delivered to the inflation side of one or more of the inflatable air chambers to seal the unsealed opening and trap the inflation gas within the chambers as the film is drawn through the sealing mechanism; and    wherein the slitting mechanism comprising a blade that slices open the relatively narrow longitudinally extending channel of the plastic film to allow the film to disengage from the elongate member as the film is drawn through the slitting mechanism.