Abstract: A method for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: A heat-seal device generally includes a heat source, a thermal conductor, which encapsulates at least a portion of the heat source and is capable of transferring heat from the heat source, and a thermal insulator, which substantially surrounds the thermal conductor but leaves a portion thereof exposed, the exposed portion of the thermal conductor providing a heat-seal contact surface, which is adapted to be brought into contact with a material to be sealed.

Abstract: A method for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: A method and apparatus for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: A heat-seal device generally includes a heat source, a thermal conductor, which encapsulates at least a portion of the heat source and is capable of transferring heat from the heat source, and a thermal insulator, which substantially surrounds the thermal conductor but leaves a portion thereof exposed, the exposed portion of the thermal conductor providing a heat-seal contact surface, which is adapted to be brought into contact with a material to be sealed.

Abstract: The invention is an inflatable mailer having a liner that can be inflated at the point of use. The liner includes a series of inflatable chambers that are in fluid communication with a common channel. A controlled volume of gas is disposed in the liner. The gas is sufficient to inflate the common channel but is not sufficient to appreciably inflate the inflatable chambers. As a result, the inflatable mailer is in a relatively compact state. The invention includes an apparatus for inflating the mailer. The apparatus includes a nip for moving the controlled volume of gas into the common channel; an inflation nozzle adapted to pierce the inflated common channel and introduce a second portion of gas into the liner until the liner is inflated to a desired level; and a sealing device to seal the inflated liner.

Abstract: A heat-seal device generally includes a heat source, a thermal conductor, which encapsulates at least a portion of the heat source and is capable of transferring heat from the heat source, and a thermal insulator, which substantially surrounds the thermal conductor but leaves a portion thereof exposed, the exposed portion of the thermal conductor providing a heat-seal contact surface, which is adapted to be brought into contact with a material to be sealed.

Abstract: The invention is an inflatable mailer having a liner that can be inflated at the point of use. The liner includes a series of inflatable chambers that are in fluid communication with a common channel. A controlled volume of gas is disposed in the liner. The gas is sufficient to inflate the common channel but is not sufficient to appreciably inflate the inflatable chambers. As a result, the inflatable mailer is in a relatively compact state. The invention includes an apparatus for inflating the mailer. The apparatus includes a nip for moving the controlled volume of gas into the common channel; an inflation nozzle adapted to pierce the inflated common channel and introduce a second portion of gas into the liner until the liner is inflated to a desired level; and a sealing device to seal the inflated liner.

Abstract: A molding system for foam-in-bag cushions comprises a mold defining a mold cavity, an air plenum separate from the mold cavity, a plurality of air passages that connect the mold cavity to the air plenum, and at least one port connected to the air plenum. The mold cavity has an open side and the mold includes a door that is movable between a closed position closing the open side of the mold cavity and an open position allowing a cushion to enter and exit through the open side. The system further comprises a pneumatic vacuum/blowout system connected with the at least one port. The vacuum/blowout system comprises a vacuum source, an air tank containing pressurized air, and a vacuum/blowout valve structured and arranged to alternately couple the at least one port either to the vacuum source or to the air tank.

Abstract: A machine, system and method for severing a web having a series of containers, wherein the containers are spaced apart and linked together by a series of connectors disposed between the containers. The machine generally includes a rotary device having a plurality of spaced-apart standoff members extending radially outwards to contact the web at the connectors such that rotational movement of the rotary device causes movement of the web; a severing mechanism including a movable severing device that is adapted to urge the web against one of the standoff members to thereby effect severance of the web; and a control system comprising an operator interface to allow a specified number of containers to be selected for severance from the web.

Abstract: An inflatable mailer having a liner that can be inflated at the point of use. The liner includes a series of inflatable chambers that are in fluid communication with a common channel. A controlled volume of gas is disposed in the liner. The gas is sufficient to inflate the common channel but is not sufficient to appreciably inflate the inflatable chambers. As a result, the inflatable mailer is in a relatively compact state. An apparatus for inflating the mailer. The apparatus includes a nip for moving the controlled volume of gas into the common channel; an inflation nozzle comprising a pointed needle configured to pierce the inflated common channel and introduce a second portion of gas into the liner until the liner is inflated to a desired level; and a sealing device to seal the inflated liner.

Abstract: A method and apparatus for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: A method and apparatus for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.