Abstract: A preformed web and a method of producing dunnage units from the preformed web. The web is an elongate flattened thermoplastic tube having an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. In one embodiment, the web is configured such that a gap forms between each pair of adjacent pouches when the pouches are inflated. In one embodiment, an inflation edge of the web comprises a frangible connection that allows the inflation edge to be broken by an unsharpened object.

Abstract: A methods of executing start, run, and stop sequences on a machine for converting a web of preformed pouches into inflated dunnage units. The pouches are defined by transverse seals extending from a remote edge to within a predetermined distance from an inflation edge.

Abstract: An exemplary method of making packages includes advancing a web of connected bags to a position where an opening of the bag is below an engagement device and opening the engagement device. Additionally, the exemplary method includes blowing the opening of the bag to a partially opened configuration, and reverse indexing the web of connected bags so that a portion of the engagement device is disposed inside of the bag and a portion of the engagement device is disposed outside the bag. Subsequently, the exemplary method includes closing the engagement device so that the engagement device engages the bag and moving the engagement device to a position that causes the opening of the bag to have a rectangular shape.

Abstract: An exemplary air cushion inflation machine includes: a first terminal connected to a direct current input; a second terminal; a reference resistor powered by the direct current input; an op-amp; and a transistor. The first terminal of the op-amp is connected to a variable voltage source and the second terminal of the op-amp is connected to the reference resistor. The transistor has a base connected to an output of the op-amp, an emitter connected to the reference resistor, and a collector connected to a first terminal of a sealing band apparatus having first and second terminals. A meltable material placed between the first and second terminals is melted by resistance of current flowing between the first and second terminals. The variable voltage source changes voltage based on a voltage drop measured across the first and second terminals by a voltage measurement device and the constant current.

Abstract: A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

Abstract: A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

Abstract: A conveyor system pre-inserts a portion of the web into a first belt before the portion is gripped between the first belt and a second belt. In one exemplary embodiment, a pair of lips of a web are inserted into a corresponding first pair of belts and then the pair of lips are secured in the first pair of belts by inserting a second pair of belts into the first pair of belts over the pair of lips.

Abstract: A web, method, and apparatus for forming dunnage units. The web includes first and second elongated layers. A plurality of seals that hermetically join the first elongated layer to the second elongated layer to form a plurality of inflatable pouches and an inflation channel that is in fluid communication with pouches and is disposed outside of the pouches. An inflation side line of perforations, a gap forming area, and an opposite side line of perforations are arranged in a line between pair(s) of the pouches.

Abstract: An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.

Abstract: An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.

Abstract: A machine for converting a web of preformed pouches into inflated dunnage units. The pouches are defined by transverse seals extending from a remote edge to within a predetermined distance from an inflation edge. The machine includes a tensioning device for frictional engagement with the web, an inflation arrangement for inflation of the preformed pouches, a sealing arrangement, and a clamping arrangement. The sealing arrangement may be positioned to provide a longitudinal seal that intersects the transverse seals to close the preformed pouches and form a dunnage unit. The tensioning device holds the web taught during downstream travel.

Abstract: A web, method, and apparatus for forming dunnage units. The web includes first and second elongated layers. A plurality of seals that hermetically join the first elongated layer to the second elongated layer to form a plurality of inflatable pouches and an inflation channel that is in fluid communication with pouches and is disposed outside of the pouches. An inflation side line of perforations, a gap forming area, and an opposite side line of perforations are arranged in a line between pair(s) of the pouches.

Abstract: A conveyor system pre-inserts a portion of the web into a first belt before the portion is gripped between the first belt and a second belt. In one exemplary embodiment, a pair of lips of a web are inserted into a corresponding first pair of belts and then the pair of lips are secured in the first pair of belts by inserting a second pair of belts into the first pair of belts over the pair of lips.

Abstract: A method for converting a web of preformed pouches to on-demand inflatable packaging. The method may include moving the web along a path of travel, attaching an outer skin to the outside of the web, and packaging the web into a non-inflated and stored configuration. The method may also include moving the web along a path of travel, depositing at least one product into each of a plurality of the preformed pouches, and inflating each of the preformed pouches to form a cushioning material.

Abstract: A web of expandable bags, a method for forming a web of expandable bags, and a method of forming an expandable bag containing a product is provided. The web of expandable bags includes a plurality of connected bags. Each bag includes a front ply and a back ply, and each bag is connected to an adjacent bag by a perforated connection. The front and back plies are joined to define a compartment that includes a first side, a second side, a third side that extends between the first side and the second side, and a bag opening that is configured to be closed. The front and back plies include a plurality of slits, and the plurality of slits are arranged in a plurality of spaced apart rows. The plurality of slits allows the compartment to expand in a direction that is perpendicular to the arrangement of the plurality of slits.

Abstract: In one embodiment, a packaging machine includes a mechanism for compressing one or more sides of the bag to expel excess air from an open top end of the bag. In one embodiment, a packaging machine supports a top portion of a bag and a bottom portion of the bag, such that the bottom portion of the bag is moved closer to the top portion of the bag as the bag is moved from a first location to a second location. The bags may be supported from below such that additional support is provided during compression of the bag to remove excess air.

Abstract: Methods for forming packages from a web of preformed bags. In one exemplary method of forming packages from a web of preformed bags, a first bag is held open with air. A product is loaded into the first bag that is held open with air. An opening of the first bag is sealed. A next bag is indexed such that an opening of the next bag is proximate to an engagement member. The web is engaged with the engagement member to pre-open the next bag. The web is disengaged by the engagement member. The next bag is opened with air for loading.

Abstract: An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.