Abstract: A molding apparatus for making a continuous molded article generally includes a pair of spaced-apart molding assemblies, which cooperatively generate a movable mold having a dynamic mold-cavity therein, each of the molding assemblies including a series of movable mold segments, which are adapted to fit together to form a portion of the dynamic mold-cavity, a drive mechanism for conveying the mold segments along a path, and a dispenser for dispensing a moldable, expandable material into the dynamic mold-cavity.

Abstract: A molding apparatus for making a continuous molded article or continuous series of molded articles generally includes a pair of spaced-apart molding assemblies, which cooperatively generate a movable mold having a dynamic mold-cavity therein, each of the molding assemblies including a series of movable mold segments, which are adapted to fit together to form a portion of the dynamic mold-cavity, a drive mechanism for conveying the mold segments along a path, and a dispenser for dispensing a moldable, expandable material into the dynamic mold-cavity.

Abstract: A supply structure for a supply of fan-folded sheet stock material, which is positionable relative to a cushion conversion machine to provide thereto the fan-folded sheet stock material for conversion thereof into packaging cushioning. The supply structure includes two or more supports, each of the supports including a base and a riser extending upwardly from the base. The base and the riser are structured and arranged to cooperatively accommodate a stack of the fan-folded sheet stock material.

Abstract: The cellular cushioning article comprises a thermoformed film bonded to a second film, with the thermoformed film having thermoformed regions separated by a land area. The thermoformed film has a combination of (i) a layer containing a high melt point polymer and (ii) thermoformed regions exhibit a high average maximum birefringence. The high birefringence corresponds with high stress on the polymer chains. The combination results in cells of substantially increased burst strength. The cellular cushioning article can provide higher burst strength per mil of film thickness, or can be produced using less plastic than prior art cellular cushioning articles, while maintaining the same or comparable burst strength. Also disclosed is a process for making the cellular cushioning article.

Abstract: An automated process for monitoring and controlling cleaning in a production area comprises tracking or identifying an object the production area, monitoring the movement of fluid in the production area, analyzing the interaction between the object and the fluid to determine a level of cleanliness achieved, and triggering an event based on at least one member selected from the group consisting of: (i) the interaction between the object or body part and the fluid or fluid-like medium and (ii) the level of cleanliness achieved. The event comprises at least one member selected from generating a report, activating an alarm, report, activating an alarm, inactivating equipment in the production area, and blocking access to at least a portion of the production area. The system employing a combination of computer(s), computer vision system(s), RFID tag(s), mechanical and electromechanical, chemical, electrical, or photonic device(s) to conduct the tracking, identifying, monitoring, and triggering.

Abstract: An inflatable structure may be formed from a single piece of flexible film using a provided method of manufacturing. The inflatable structure may include quilting seals which divide the inflatable chamber. The inflatable structure may also include an external valve opening extending through multiple layers of the flexible film. The external valve opening may further be partially defined by edge portions of the flexible film formed by folding the flexible film. The external valve opening may be configured to align with an opening in a container or an inflation aperture in a pouch so that the inflatable structure can be inflated while inside the container/pouch. A corresponding inflation device fills the inflatable structure with air and may do so without requiring heat sealing or contact between the inflatable structure and outlet of the inflation device. A hinged plate apparatus may assist in directing air into the external valve opening.

Abstract: A machine for inflating and sealing an inflatable structure having a longitudinal edge generally comprises a drive, an inflation nozzle, a sealing device, and a sheet engagement device. The machine may define an engaging assembly and an opposing assembly. The drive may be rotationally coupled to the sheet engagement device such that when the drive rotates, the engagement device also rotates. The sheet engagement device may comprise one or more engagement rollers which may have a plurality of teeth thereon. A first plurality of rollers and a second plurality of rollers comprising the engagement rollers may intermesh between a drive roller and a backing roller on the longitudinal edge of the inflatable structure. Thereby, the sheets of the inflatable structure may be engaged together and the length of the longitudinal edge may contract to facilitate inflation. The resulting inflated inflatable structure may comprise an embossed longitudinal edge.

Abstract: A machine for inflating and sealing an inflatable web, the web including opposing longitudinal edges and a pair of sheets sealed together by transverse seals that form a series of inflatable containers. The machine generally includes a support structure, a spool for supporting a roll of the inflatable web, a web conveyance system, an inflation system to inflate the containers, and a sealing device for sealing closed the openings of the containers.

Abstract: A machine for inflating and sealing an inflatable structure having a longitudinal edge generally comprises a drive, an inflation nozzle, a sealing device, and a sheet engagement device. The machine may define an engaging assembly and an opposing assembly. The drive may be rotationally coupled to the sheet engagement device such that when the drive rotates, the engagement device also rotates. The engagement device may include a first belt and an opposing second belt which may each have a plurality of teeth thereon. The teeth may intermesh between a drive roller and a backing roller on the longitudinal edge of the inflatable structure. Thereby, the sheets of the inflatable structure may be engaged together and the length of the longitudinal edge may contract to facilitate inflation. The resulting inflated inflatable structure may comprise an embossed longitudinal edge.

Abstract: A fluid dispensing device has a container made from a flexible material defining an interior fluid storage region and a flexible metering housing having a metering chamber in fluid communication with the fluid storage region, the flexible metering housing having a button heat sealed to a base plate. A unidirectional intake valve is disposed between the container and the flexible metering housing. A unidirectional output valve is in fluid communication with the flexible metering housing. The button has a stepped flange towards an outer edge of said circular shape and the base plate has a stepped flange corresponding to the stepped flange of the button.

Abstract: A dispensing and sealing system generally includes a film-feed assembly with a support mechanism for a supply of film and a film-drive mechanism to advance the film along a path, a dispenser with an outlet port for dispensing fluid into the film, and a transverse seal mechanism for forming a seal in the film transversely of the path. A calendering device and a movable structure for the support mechanism are also described.

Abstract: A system for producing packaging cushioning generally includes a cushion conversion machine and a supply structure for a stack of fan-folded sheet stock material. The structure is positioned relative to the machine to supply thereto the fan-folded sheet stock material for conversion thereof into packaging cushioning, and includes an inclined, load-bearing support. The load-bearing support includes a base and a riser extending upwardly from the base, the base and the riser being structured and arranged to cooperatively accommodate the stack of fan-folded sheet stock material such that the sheet stock material is supplied to the cushion conversion machine from a top of the stack and a bottom of the stack is supported by the base. The riser is inclined at an angle relative to vertical such that the stack of fan-folded sheet stock material is also inclined at the angle, whereby, the stack is urged against the riser by force of gravity.

Abstract: A packaging cushion insert is useful for cushioning a packaged object. The insert comprises a top sheet, a bottom sheet; and a plurality of interior sheets between the top and bottom sheets. The top sheet, the bottom sheet, and the plurality of interior sheets are in stacked and laminated arrangement. The top sheet, bottom sheet, and plurality of interior sheets each comprise one or more materials selected from an air-cellular cushioning material, cellular foam material, and crumpled paper material.

Abstract: A method of making a foam from a polymerizable resin includes the following steps. A thermally-activated initiator having a temperature below the initiation temperature is combined with an elevated-temperature solution having the polymerizable resin and carbon dioxide at a temperature above a promoted temperature to create a resulting mixture having a temperature above the promoted temperature. The resulting mixture is expanded by decreasing the pressure of the mixture to create a froth having a plurality of cells formed by carbon dioxide that expanded out of solution. The polymerizable resin within the froth is cured to create a foam.

Abstract: A dispensing and sealing system generally includes a film-feed assembly with a support mechanism for a supply of film and a film-drive mechanism to advance the film along a path, a dispenser with an outlet port for dispensing fluid into the film, and a transverse seal mechanism for forming a seal in the film transversely of the path. A calendering device and a movable structure for the support mechanism are also described.

Abstract: The invention is directed to an apparatus and method for inflating and sealing a mailer comprising an inner inflatable liner having at least one inflation port, valve, or combination thereof through which a portion of gas can be introduced into the liner.

Abstract: The cellular cushioning article comprises a thermoformed film bonded to a second film, with the thermoformed film having thermoformed regions separated by a land area. The thermoformed film has a combination of (i) a layer containing a high melt point polymer and (ii) thermoformed regions exhibit a high average maximum birefringence. The high birefringence corresponds with high stress on the polymer chains. The combination results in cells of substantially increased burst strength. The cellular cushioning article can provide higher burst strength per mil of film thickness, or can be produced using less plastic than prior art cellular cushioning articles, while maintaining the same or comparable burst strength. Also disclosed is a process for making the cellular cushioning article.

Abstract: A packaging system includes a retention frame and a tray. The retention frame includes a panel and a retention sheet. The panel has a first fold line defining a first flap and a remainder portion. The remainder portion defines a panel opening. The retention sheet is attached to the first flap and the remainder portion so that the retention sheet extends over the panel opening and the first fold line. The tray includes a tray frame defining a tray opening. A tray sheet is attached to the tray frame and extends over the tray opening. The tray is configured for positioning between the retention sheet and the remainder portion of the retention frame to juxtapose the tray opening with the panel opening. A product may be supported on the tray sheet to suspend and retain the product between the retention sheet and the tray sheet over the juxtaposed tray and panel openings.

Abstract: A cushioning assembly includes a first sheet and a second sheet opposing the first sheet. A plurality of foam elements are between the first and second sheets and adhered to at least one of the first sheet interior surface and the second sheet interior surface. The aspect ratio of the plurality of foam elements is at least 1.2.

Abstract: Various embodiments of the present invention are directed to systems for dispensing multiple types of materials, such as packing materials. According to various embodiments, the systems include a dispensing bin with multiple compartments configured to receive and dispense different types of materials, such as air-filled dunnage cushions and air-filled protective material. In certain embodiments, the dispensing bin is configured to receive materials from one or more supply machines and dispense the materials such that more than one type of material is provided to numerous packing stations for use in packaging items.