Apparatus for forming inflated packaging cushions

Abstract

An inflation apparatus automatically inflates and seals a plurality of pockets preformed in a film web to form packaging cushions. As the film web is advanced, a stream of inflation gas is directed from an inflation port into each of the pockets. The steam of inflation gas is directed in a flow direction having a component in the direction of travel. A sealing mechanism is positioned as close as possible to the inflation port so that the opening of each pocket is almost entirely closed and sealed while the stream of inflation gas is directed into the pocket. As a result, it is possible to achieve more fully inflated packaging cushions on a consistent basis.

1 . An apparatus for forming inflated cushions, comprising: 
 a film web defining a plurality of preformed pockets, each pocket having an opening;    a transport mechanism operable to convey the film web along a transport path in a direction of travel;    an inflation mechanism positioned adjacent the transport path and having a first outlet port operable to direct a first stream of inflation gas into each of the pockets to form inflated cushions, the first stream of inflation gas being directed in a flow direction, the flow direction having a component in the direction of travel; and    a sealing mechanism operable to seal closed the opening of each pocket.    
     
     
         2 . The apparatus as claimed in  claim 1 , wherein the flow direction has a component in a direction orthogonal to the direction of travel.  
     
     
         3 . The apparatus as claimed in  claim 2 , wherein the component in the direction of travel is greater than the component in the direction orthogonal to the direction of travel.  
     
     
         4 . The apparatus as claimed in  claim 1 , wherein the inflation mechanism further includes a second outlet port operable to direct a second stream of inflation gas into each of the pockets, the second stream of inflation gas flowing in a direction substantially orthogonal to the direction of travel.  
     
     
         5 . The apparatus as claimed in  claim 1 , wherein the sealing mechanism includes a pair of opposed members defining a nip therebetween, at least one of the opposed members including a roller, and at least a portion of the first outlet port being positioned between the nip and an imaginary vertical line tangential to the roller.  
     
     
         6 . The apparatus as claimed in  claim 1 , wherein the inflation gas is air, the apparatus further comprising a gas ring compressor for supplying pressurized air to the inflation mechanism.  
     
     
         7 . The apparatus as claimed in  claim 1 , wherein the flow direction is at an angle to the direction of travel of between about 5° and 60°.  
     
     
         8 . The apparatus as claimed in  claim 7 , wherein the angle is between about 5° and about 30°.  
     
     
         9 . The apparatus as claimed in  claim 8 , wherein the angle is about 11°.  
     
     
         10 . The apparatus as claimed in  claim 1 , wherein the transport mechanism includes a first portion operable to convey the film web past the inflation mechanism in the direction of travel and a second portion operable to convey the film web past the sealing mechanism, the first portion being different than the second portion.  
     
     
         11 . The apparatus as claimed in  claim 10 , wherein the first portion conveys the film web at a first transport speed, and the second portion conveys the film web at a second transport speed slower than the first transport speed.  
     
     
         12 . The apparatus as claimed in  claim 10 , wherein the second portion conveys the film web in a direction transverse to the direction of travel.  
     
     
         13 . The apparatus as claimed in  claim 10 , wherein the first portion conveys the film web with a first tension and the second portion conveys the film web with a second tension less than the first tension.  
     
     
         14 . An apparatus for forming inflated cushions, comprising: 
 a film web defining a plurality of preformed pockets, each pocket having an opening;    a transport mechanism operable to convey the film web along a transport path in a direction of travel;    an inflation mechanism positioned adjacent the transport path and having a first outlet port operable to direct a first stream of inflation gas into each of the pockets to form inflated cushions; and    a sealing mechanism operable to seal closed the opening of each pocket, the sealing mechanism including a pair of opposed members defining a nip therebetween, at least one of the opposed members including a roller, and at least a portion of the first outlet port being positioned between the nip and an imaginary vertical line tangential to the roller.    
     
     
         15 . The apparatus as claimed in  claim 14 , wherein the inflation mechanism further includes a second outlet port operable to direct a second stream of inflation gas into each of the pockets, the second stream of inflation gas flowing in a direction substantially orthogonal to the direction of travel.  
     
     
         16 . The apparatus as claimed in  claim 14 , wherein the transport mechanism includes a first portion operable to convey the film web past the inflation mechanism in the direction of travel and a second portion operable to convey the film web past the sealing mechanism in a direction transverse to the direction of travel.  
     
     
         17 . The apparatus as claimed in  claim 14 , wherein the transport mechanism includes a first portion operable to convey the film web past the inflation mechanism at a first transport speed and a second portion operable to convey the film web past the sealing mechanism at a second transport speed slower than the first transport speed.  
     
     
         18 . The apparatus as claimed in  claim 14 , wherein the transport mechanism includes a first portion operable to convey the film web past the inflation mechanism with a first tension and a second portion operable to convey the film web past the sealing mechanism with a second tension less than the first tension.  
     
     
         19 . A method for forming inflated cushions, comprising: 
 providing a film web defining a plurality of preformed pockets, each pocket having an opening;    conveying the film web along a transport path in a direction of travel;    directing a first stream of inflation gas into each of the pockets to form inflated cushions, the first stream of inflation gas being directed in a flow direction, the flow direction having a component in the direction of travel; and    sealing closed the opening of each pocket.    
     
     
         20 . The method as claimed in  claim 19 , wherein the step of sealing closed the opening of a selected pocket is initiated while the first stream of inflation gas is directed into the selected pocket.  
     
     
         21 . The method as claimed in  claim 19 , wherein the flow direction has a component in a direction orthogonal to the direction of travel.  
     
     
         22 . The method as claimed in  claim 21 , wherein the component in the direction of travel is greater than the component in the direction orthogonal to the direction of travel.  
     
     
         23 . The method as claimed in  claim 19 , further comprising directing a second stream of inflation gas into each of the pockets, the second stream of inflation gas flowing in a direction substantially orthogonal to the direction of travel.  
     
     
         24 . The method as claimed in  claim 19 , wherein the flow direction is at an angle to the direction of travel of between about 5° and about 60°.  
     
     
         25 . The method as claimed in  claim 24 , wherein the angle is between about 5° and about 30°.  
     
     
         26 . The method as claimed in  claim 25 , wherein the angle is about 11°.  
     
     
         27 . The method as claimed in  claim 19 , wherein the conveying step includes conveying the film web past the inflation mechanism in the direction of travel and conveying the film web past the sealing mechanism in a direction transverse to the direction of travel.  
     
     
         28 . The method as claimed in  claim 19 , wherein the conveying step includes conveying the film web past the inflation mechanism at a first transport speed and conveying the film web past the sealing mechanism at a second transport speed slower than the first transport speed.  
     
     
         29 . The method as claimed in  claim 19 , wherein the conveying step includes conveying the film web past the inflation mechanism with a first tension and conveying the film web past the sealing mechanism with a second tension less than the first tension.