111111111111111111111111111111111111111111111111111111111111111111111111111
`US007757459B2
`
`c12) United States Patent
`Wehrmann
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7,757,459 B2
`Jul. 20, 2010
`
`(54) WEB AND METHOD FOR MAKING FLUID
`FILLED UNITS
`
`(75)
`
`Inventor: Rick Steven Wehrmann, Hudson, OH
`(US)
`
`(73) Assignee: Automated Packaging Systems, Inc.,
`Streetsboro, OH (US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 771 days.
`
`(21) Appl. No.: 11/141,304
`
`(22) Filed:
`
`May 31,2005
`
`(65)
`
`Prior Publication Data
`
`US 2005/0266189 Al
`
`Dec. 1, 2005
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/576,004, filed on Jun.
`1, 2004, provisional application No. 60/592,812, filed
`on Jul. 30, 2004.
`
`(51)
`
`Int. Cl.
`B65B 31100
`(2006.01)
`(52) U.S. Cl. .................... 53/403; 53/79; 383/3; 428/43
`(58) Field of Classification Search . ... ... ... ... .. ... ... 53/79,
`53/403, 473, 562; 156/145, 147, 497, 498;
`383/3; 428/43
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5/1962 Weber
`3,033,257 A
`6/1966 Lerner
`3,254,820 A
`6/1966 Lerner
`3,254,828 A
`111967 Lerner
`3,298,156 A
`12/1967 Paxton
`3,358,823 A
`3,359,703 A * 12/1967 Quaadgras ................... 53/493
`6/1968 Pendleton
`3,389,534 A
`3,414,140 A
`12/1968 Feldkamp
`
`18
`
`3,462,027 A
`3,477,196 A
`3,523,055 A
`3,575,757 A
`3,575,781 A
`3,577,305 A
`
`8/1969
`1111969
`8/1970
`4/1971
`4/1971
`5/1971
`
`Puckhaber
`Lerner
`Lemelson
`Smith
`Pezely
`Hines eta!.
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`
`2428246
`
`9/2002
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`International Search Report and Written Opinion from Internatonal
`Application No. PCT/US 2005/18817, dated Mar. 30,2007, 6 pages.
`
`(Continued)
`
`Primary Examiner-Thanh K Truong
`(74) Attorney, Agent, or Firm-Calfee, Halter & Griswold
`LLP
`
`(57)
`
`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 infla(cid:173)
`tion edge of the web comprises a frangible connection that
`allows the inflation edge to be broken by an unsharpened
`object.
`
`15 Claims, 7 Drawing Sheets
`
`Page 001
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`US 7,757,459 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`156/497
`
`10/1971 Chavannes
`3,616,155 A
`3,618,286 A
`1111971 Membrino
`3/1972 Johnson
`3,650,877 A
`5/1972 Troy
`3,660,189 A
`6/1972 Pendleton
`3,667,593 A
`5/1973 Presnick
`3,730,240 A
`7/1973 Titchenal eta!.
`3,744,211 A
`2/1974 Titchenal eta!.
`3,791,573 A
`3/1974 Armstrong et a!.
`3,795,163 A
`4/1974 Emmel ........................ 156/55
`3,802,974 A
`5/1974 Shaw
`3,808,981 A
`6/1974 Weikert
`3,813,845 A
`6/1974 Horsley
`3,817,803 A
`9/1974 McConell et a!.
`3,837,990 A
`9/1974 Evans
`3,837,991 A
`12/1974 Irnhagen et a!.
`3,855,037 A
`2/1976 Luhman et al.
`3,938,298 A
`2/1976 Baxter
`3,939,995 A
`3/1976 Weikert
`3,941,306 A
`3/1977 Lerner
`4,014,154 A
`4/1977 Larson eta!.
`4,017,351 A
`5/1977 Weikert
`4,021,283 A
`8/1977 Baxter eta!.
`4,040,526 A
`8/1977 Ramsey, Jr.
`4,044,693 A
`2/1978 Lewicki eta!.
`4,076,872 A
`6/1978 Larson
`4,096,306 A
`8/1978 Lowdermilk
`4,103,471 A
`3/1979 Angarola eta!.
`4,146,069 A
`9/1979 Larson
`4,169,002 A
`5/1980 Lerner
`4,201,029 A
`12/1981 Dahlem
`4,306,656 A
`2/1982 Ottaviano
`4,314,865 A
`10/1982 Hughes eta!.
`4,354,004 A
`4,493,684 A *
`111985 Bolton ....................... 493/234
`5/1985 Eichbauer et al.
`4,518,654 A
`10/1985 Chung eta!.
`4,545,180 A
`111986 Tsurata
`4,564,407 A
`3/1986 Caputo
`4,576,669 A
`7/1986 Pharo
`4,597,244 A
`4,616,472 A * 10/1986 Owensby et a!. .............. 53/459
`4,619,635 A
`10/1986 Ottaviano
`4,676,376 A
`6/1987 Keiswetter
`4,787,755 A
`1111988 Branson
`12/1988 Pharo
`4,793,123 A
`4,847,126 A
`7/1989 Yamashiro et a!.
`4,874,093 A
`10/1989 Phara
`2/1990 Campbell et a!.
`4,904,092 A
`4,918,904 A
`4/1990 Pharo
`5/1990 Chow eta!.
`4,922,687 A
`6/1990 Leeds
`4,931,033 A
`5,041,317 A
`8/1991 Greyvenstein
`5,070,675 A
`12/1991 Chuan-Shiang ................ 53/79
`6/1992 Nease eta!.
`5,117,608 A
`5,141,494 A
`8/1992 Danforth et a!.
`111993 Watts
`5,181,614 A
`5,188,691 A
`2/1993 Caputo
`4/1993 Reichental et a!.
`5,203,761 A
`5,210,993 A
`5/1993 van Boxtel
`5,216,868 A
`6/1993 Cooper et al.
`5,257,492 A
`1111993 Watts
`5,272,856 A
`12/1993 Pharo
`5,289,671 A
`3/1994 Lerner
`5,307,969 A * 5/1994 Menendez ................... 225/42
`5,340,632 A
`8/1994 Chappuis ..................... 428171
`5,351,828 A
`10/1994 Becker et al.
`5,383,837 A
`111995 Watts
`5,394,676 A
`3/1995 Lerner
`5,454,642 A
`10/1995 DeLuca
`5,468,525 A
`1111995 Watts
`5,470,300 A
`1111995 Terranova
`5,552,003 A
`9/1996 Hoover eta!.
`
`7/1997 DeLuca
`5,651,237 A
`12/1997 Hoover eta!.
`5,693,163 A
`12/1997 Hartman et a!. ............... 53/455
`5,699,653 A
`3/1998 Jostler eta!. .................. 383/37
`5,733,045 A
`5/1998 DeLuca
`5,755,328 A
`5,810,200 A * 9/1998 Trokhan ...................... 221155
`10/1998 Gotoh eta!.
`5,824,392 A
`5,921,390 A * 7/1999 Sirnhaee ..................... 206/390
`RE36,501 E
`1/2000 Hoover eta!.
`6,015,047 A
`1/2000 Greeland
`6,015,357 A
`1/2000 Ricci
`7/2000 Hoover eta!.
`RE36,759 E
`6,199,349 B1
`3/2001 Lerner
`6,209,286 B1
`4/2001 Perkins et a!.
`6,282,716 B1
`9/2001 Patterson et a!.
`6,367,975 B1
`4/2002 Cronauer et a!.
`6,410,119 B1
`6/2002 DeLuca eta!.
`6,460,313 B1
`10/2002 Cooper
`6,488,222 B1 * 12/2002 West eta!. ............... 242/160.4
`12/2002 Cronauer et a!.
`6,499,278 B2
`6,519,916 B1
`2/2003 Brown
`6,527,147 B2
`3/2003 Wehrmann
`4/2003 Sperry eta!.
`6,550,229 B2
`6,565,946 B2
`5/2003 Perkins et a!.
`6,582,800 B2
`6/2003 Fuss et al.
`6,625,956 B1
`9/2003 Soudan ........................ 53/455
`10/2003 Borchard et a!.
`D480,646 S
`D480,971 S
`10/2003 DeLuca eta!.
`6,635,145 B2
`10/2003 Cooper .................... 156/441.5
`6,659,150 B1
`12/2003 Perkins et a!.
`112004 Wehrmann
`6,672,037 B2
`6/2004 DeLuca eta!.
`D490,711 S
`6,751,926 Bl
`6/2004 Cooper
`6,761,960 B2
`7/2004 DeLuca eta!.
`9/2004 Fuss et al ...................... 53/403
`6,786,022 B2
`5/2005 Lerner eta!.
`6,889,739 B2
`6,948,296 B1
`9/2005 Lerner eta!.
`6,952,910 B1
`10/2005 Lorsch
`10/2005 Lerner
`6,955,846 B2
`D512,311 S
`12/2005 DeLuca eta!.
`D513,182 S
`12/2005 DeLuca eta!.
`10/2006 Lerner eta!.
`7,125,463 B2
`1/2007 O'Dowd ........................ 53/96
`7,165,375 B2
`7,223,462 B2
`5/2007 Perkins et a!.
`7,533,772 B2
`5/2009 Yo shifusa et a!.
`7,550,191 B2
`6/2009 Lerner
`7,571,584 B2
`8/2009 Lerner eta!.
`D603,705 S
`1112009 Wehrmann
`200110000719 A1
`5/2001 Lerner
`200110014980 A1
`8/2001 Patterson et a!.
`2002/0108697 A1
`8/2002 Perkins et a!.
`2002/0155246 A1
`10/2002 Johnson et al.
`2004/0265523 A1
`12/2004 Koyanagi et a!.
`2005/0266189 A1
`12/2005 Wehrmann
`2006/0042191 A1
`3/2006 Lerner
`2006/0086064 A1
`4/2006 Wehrmann
`2006/0090421 A1
`5/2006 Sperry eta!. .................. 53/403
`2007/0054074 A1
`3/2007 Wehrmann
`2007/0054075 A1
`3/2007 Wehrmann
`2009/0110864 A1
`4/2009 Wehrmann
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`wo
`wo
`wo
`wo
`wo
`wo
`
`1466 720 A2
`WO 00171423 A1
`01153153
`WO 01185434 A2
`WO 02/26589 A1
`2005/118408
`2007/070240
`
`10/2004
`1112000
`7/2001
`1112001
`4/2002
`12/2005
`6/2007
`
`Page 002
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`US 7,757,459 B2
`Page 3
`
`wo
`
`2009/058749
`
`5/2009
`
`OTHER PUBLICATIONS
`
`Office action from U.S. Appl. No. 111299,933, mailed Sep. 16,2008.
`Office actwn from U.S. Appl. No. 111194,375, mailed Sep. 19,2008.
`USPTO Non-Final Office Action having a mailing date of Mar. 19,
`2008 in co-pending U.S. Appl. No. 111299,933, filed Dec. 12, 2005.
`Internatwnal Search Report and Written Opinion from Internatonal
`Application No. PCT/US 2006/045447, dated Feb. 22, 2007, 10
`pages.
`Office action from U.S. Appl. No. 111194,375, mailed Jun. 2, 2008.
`Office action from U.S.Appl. No. 111194,375, mailed Nov. 20,2007.
`Advisory actwn from U.S. Appl. No. 111194,375, mailed Oct. 9
`2007.
`'
`Office action from U.S.Appl. No. 111194,375, mailed Aug. 21,2007.
`Office action from U.S. Appl. No. 111194,375, mailed Feb. 6, 2007.
`Office actwn from U.S. Appl. No. 111194,375, mailed Nov. 13, 2006.
`Office actwn from U.S. Appl. No. 111299,933, mailed Dec. 18, 2008.
`Amendment from U.S. Appl. No. 111194,375 dated May 4, 2007.
`Amendment from U.S. Appl. No. 111194,375 dated Oct. 2, 2007.
`Amendment from U.S. Appl. No. 111194,375 dated Feb. 29, 2008.
`Amendment from U.S. Appl. No. 111194,375 dated Aug. 4, 2008.
`Advisory Action from U.S. Appl. No. 111194,375 dated Aug. 12
`2008.
`'
`Amendment from U.S. Appl. No. 111194,375 dated Dec. 19, 2008.
`Response from U.S. Appl. No. 111299,933 dated Jun. 3, 2008.
`Response from U.S. Appl. No. 111299,933 dated Nov. 17, 2008.
`Notice of Allowance from U.S. Appl. No. 111194,375 dated Apr. 10
`2009.
`'
`Amendment from U.S. Appl. No. 111299,933 dated Mar. 6, 2009.
`International Search Report and Written Opinion from PCT/US08/
`81410 dated Mar. 31, 2009.
`Office action from U.S. Appl. No. 111299,933 dated Jun. 12, 2009.
`
`Office action from U.S. Appl. No. 111299,933 dated Dec. 31, 2009.
`Office action from U.S. Appl. No. 111496,654 dated Jan. 13, 2010.
`Notice of Allowance from U.S. Appl. No. 111496,645 dated Jan. 4
`2010.
`'
`Notice of Allowance from U.S. Appl. No. 10/408,947 dated Dec. 21
`2004.
`'
`Office action from U.S. Appl. No. 111111,164 dated Apr. 27, 2006.
`Response from U.S. Appl. No. 111111,164 dated Jul. 17, 2006.
`Notice of Allowance from U.S. Appl. No. 111111,164 dated Aug. 23
`2006.
`'
`Response from U.S. Appl. No. 111299,933 dated Dec. 9, 2009.
`Office action from U.S. Appl. No. 111496,654 dated Apr. 1, 2009.
`Response from U.S. Appl. No. 111496,654 dated Jun. 26, 2009.
`Office action from U.S. Appl. No. 111496,654 dated Aug. 11, 2009.
`Response from U.S. Appl. No. 111496,654 dated Dec. 11, 2009.
`Office action from U.S. Appl. No. 111496,645 dated Aug. 31, 2009.
`Response from U.S. Appl. No. 111496,645 dated Nov. 30,2009.
`Office action from U.S. Appl. No. 12/507,220 dated Oct. 22, 2009.
`One page drawing, Briggs Bag 1, illustrates a web of pre-formed bags
`sold by Applicant for use in Applicant's SP machines more than one
`year prior to the priority date of the present application. Operation of
`Applicant's SP machines is disclosed by U.S. Patent Nos. 4,969,310;
`5,743,070; 5,944,424; 5,722,218; and 6,035,611.
`One page drawing, Goody Bag 1, illustrates a web of pre-formed bags
`sold by Applicant for use in Applicant's SP machines more than one
`year prior to the priority date of the present application. Operation of
`Applicant's SP machines is disclosed by U.S. Patent Nos. 4,969,310;
`5,743,070; 5,944,424; 5,722,218; and 6,035,611.
`International Search Report and Written Opinion from PCT/US09/
`38344 dated Dec. 22, 2009.
`Notice of Allowance from U.S. Appl. No. 29/332,921 dated Aug. 11,
`2009.
`* cited by examiner
`
`Page 003
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`U.S. Patent
`
`Jul. 20, 2010
`
`Sheet 1 of7
`
`US 7,757,459 B2
`
`"'
`"'
`00
`"'
`A
`\
`:
`r----\ ----f---------------------------------i------------- -1-
`'
`'
`l-··--·------------------------------------------·------·----~
`
`~I
`
`....... -....... ""\
`' '
`--.-
`'
`- - - . -
`
`N
`N
`
`r--------------------------------------\-------------------.-
`
`--t r:::: "-----------------;;. --------------}-:::: T::::f
`
`(()
`N
`
`00
`N
`
`..q-
`N
`
`:
`:
`'
`' ' '
`___._
`
`0
`N
`
`Page 004
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`U.S. Patent
`
`Jul. 20, 2010
`
`Sheet 2 of7
`
`US 7,757,459 B2
`
`N
`N
`
`I
`
`· \
`
`CO
`N
`
`, ____ l -----f--- --------------~--------------i-------------_:_
`--·----------
`-------------·
`'
`'
`L--·-···--·--··-------------~--------------------------------~
`-,-
`
`•
`
`'
`
`-·-·---~
`
`' ' ' ' '
`
`--.--
`'
`
`~I
`
`' I
`
`I
`I
`I
`I
`I
`
`tO
`
`C\1
`
`-~ u..
`
`N
`N
`
`I
`I
`
`:
`'
`
`,--------------------------------------~-------------------l
`·1~~(1"-~~~~~1.-··--------------;;--------------)-~~~-~~~~~~~
`
`tO
`N
`
`CX)
`N
`
`N
`
`I
`
`:
`' I
`
`I
`I
`
`Page 005
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`U.S. Patent
`
`Jul. 20, 2010
`
`Sheet 3 of7
`
`US 7,757,459 B2
`
`11
`
`)
`
`Fig.3
`
`Fig.4
`
`Fig.5
`
`Fig.6
`
`18
`
`20
`18
`(
`
`20
`18
`
`SEAL
`
`30
`
`26-: . . .
`
`CUT
`
`28
`
`Page 006
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`U.S. Patent
`
`Jul. 20, 2010
`
`Sheet 4 of7
`
`US 7,757,459 B2
`
`0
`
`<(
`
`0
`N
`
`r ................ ---- ------------------
`---~------~--
`
`~-r -~ --- ---t·-- ~;------- - ----l-----~
`
`I
`I
`
`I
`. , -
`I
`~
`I
`---------------------------:-
`-----~-----~
`
`N co
`
`0 co
`
`I
`
`I :
`
`I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`
`I i I
`
`I
`I
`I
`
`----------------+----k:_ ___ ___________________ ,
`--- -:· _:::::_ --------- -----'\:.::.:~ - ________ :::::r::::r
`f fo
`
`N
`
`Page 007
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`U.S. Patent
`
`Jul. 20, 2010
`
`Sheet 5 of7
`
`US 7,757,459 B2
`
`0 ...-
`
`0
`('I
`
`co
`co
`
`00 co
`
`r--- ------------------------
`
`---.:.-------=x--
`
`~-rr- --t -----n------___________ l ____ -!
`
`;
`...-
`:
`co
`-------- __ .................... _ ... ___ ------l-
`-----~-----~
`
`0
`00
`
`en
`1'.
`.g,
`lL
`
`00
`
`Page 008
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`64
`
`~
`00 .
`
`~
`~
`~
`
`~ = ~
`
`2' :-
`
`N
`~0
`N
`
`0 ....
`
`0
`
`('D
`('D
`
`rFJ =(cid:173)
`.....
`0\
`0 .....
`-....l
`
`d
`rJl
`-....l
`~ u.
`-....l
`~ u.
`\C = N
`
`Page 009
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`U.S. Patent
`
`Jul. 20, 2010
`
`Sheet 7 of7
`
`US 7,757,459 B2
`
`<.0
`
`CD
`
`(
`0)
`10
`
`Page 010
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`US 7,757,459 B2
`
`1
`WEB AND METHOD FOR MAKING FLUID
`FILLED UNITS
`
`RELATE BACK
`
`The present application claims priority from provisional
`patent applications Ser. No. 60/576,004, entitled "Web for
`Fluid Filled Unit Formation," filed on Jun. 1, 2004, and pro(cid:173)
`visional patent application Ser. No. 60/592,812, entitled "Air
`Pouch Machine," filed on Jul. 30, 2004. Provisional patent
`applications Ser. Nos. 60/576,004 and 60/592,812 are incor(cid:173)
`porated herein by reference in their entirety.
`
`FIELD OF THE INVENTION
`
`The present application relates to fluid filled units and more
`particularly to plastic webs of interconnected pouches and to
`processes of converting interconnected pouches to fluid filled
`units.
`
`BACKGROUND
`
`Machines for forming and filling dunnage units from
`sheets of plastic are known. Machines which produce dun(cid:173)
`nage units by inflating preformed pouches in a preformed
`web are also known. For many applications, machines which
`utilize preformed webs are preferred.
`Typically, the entire length of sides of adjacent dunnage
`units formed from a preformed web are connected by perfo(cid:173)
`rations. To separate adjacent units, a worker grasps an edge of
`one unit with one hand, grasps an edge of an adjacent unit
`with the other hand, and carefully tears the dunnage units
`apart to separate the adjacent dunnage units.
`
`SUMMARY
`
`2
`In one embodiment, an inflated volume is maintained in
`each air pouch by blowing air into an inflation opening of
`each pouch until substantially the entire inflation opening of
`the pouch is sealed. In one embodiment, the inflation opening
`is closed at a closing location located along the web path of
`travel. Air is provided into each pouch from a position slightly
`upstream of the closing location to maintain inflation of the
`pouch until it is sealed. For example, the inflation is main(cid:173)
`tained by blowing air into the inflation opening until the a
`10 trailing transverse seal of the pouch is within 0.250 inches of
`the closing position.
`In one embodiment, inflated dunnage unit arrays comprise
`a single row of interconnected inflated pouches. The pouches
`are defined by first and second layers connected together at an
`15 inflation edge, an opposite edge seal, and by a pair of seals
`that are generally transverse to the inflation edge and the
`opposite edge. Each pair of adjacent inflated pouches are
`connected by an inflation edge line of perforations that
`extends inward and generally perpendicular to the inflation
`20 edge and an opposite edge line of perforations that extends
`inward and generally perpendicular to the opposite edge. The
`inflation edge line of perforations and the opposite edge line
`of perforations are spaced apart by a gap that allows a worker
`to insert an object, such as a hand, to easily separate the pair
`25 of adjacent inflated dunnage units.
`In one embodiment, a web for forming dunnage units com(cid:173)
`prises a first elongated layer and a second elongated layer
`superposed over the first elongated layer. The first and second
`layers are connected by a frangible connection that extends
`30 along an inflation edge and a hermetic seal that extends along
`an opposite edge. The frangible connection at the inflation
`edge is configured to break when engaged by a blunt surface.
`A plurality of transverse seals extend from the hermetic seal
`to within a predetermined distance from the frangible con-
`35 nection. The hermetic seal and said transverse seals form a
`plurality of inflatable pouches.
`Further advantages and benefits will become apparent to
`those skilled in the art after considering the following descrip(cid:173)
`tion and appended claims in conjunction with the accompa-
`40 nying drawings.
`
`45
`
`The present invention relates to plastic webs of intercon(cid:173)
`nected pouches and processes of converting interconnected
`pouches to at least one row of dunnage units. In one embodi(cid:173)
`ment, upon inflation of the pouches, a gap develops between
`each pair of adjacent fluid filled pouches. This gap remains
`after the fluid filled pouches are converted to dunnage units.
`The gap between each pair of dunnage units makes separating
`adjacent pouches easier and more efficient than with existing
`interconnected arrays of dunnage units.
`In one embodiment, dunnage units are formed from a pre(cid:173)
`formed flattened tubular web that includes a plurality of
`pouches defined by a plurality of transverse seals. As pouches
`are inflated, a gap forming area between adjacent pouches
`ruptures or otherwise separates. A gap is formed between 50
`newly formed and adjacent dunnage units. In one embodi(cid:173)
`ment, the gap runs between an inflation edge line of perfora(cid:173)
`tions and a spaced apart opposite edge line of perforations.
`Pouches are converted to dunnage units by inflating the pouch
`with a fluid, substantially maintaining the inflated volume of 55
`the pouch, and hermetically sealing an inflated pouch.
`The gap between the inflation edge line of perforations and
`the spaced apart opposite edge line of perforations makes
`separating the dunnage units much simpler and easier than
`separating dunnage units that are connected by a continuous 60
`line ofun-ruptured perforations. In the present invention, to
`separate adjacent dunnage units, a worker simply inserts a
`hand or hands into the gap between adjacent dunnage units
`and applies forces on one or both of the dunnage units, which
`are connected only by the spaced apart lines of perforations. 65
`As the spaced apart lines of perforations rupture or otherwise
`separate the adjacent dunnage units are separated.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 illustrates a web for making fluid filled units;
`FIG. 2 illustrates a web for making fluid filled units;
`FIG. 3 illustrates a web with pouches inflated and sealed to
`form fluid filled units;
`FIG. 4 illustrates a web for making fluid filled units;
`FIG. 5 illustrates a web for making fluid filled units;
`FIG. 6 illustrates a web for making fluid filled units;
`FIG. 7 A schematically illustrates a plan view of a process
`and machine for converting web pouches to fluid filled units;
`FIG. 7B schematically illustrates a plan view of a process
`and machine for converting web pouches to fluid filled units;
`FIG. SA schematically illustrates anelevational view of the
`process and machine for converting web pouches to fluid
`filled units;
`FIG. SB schematically illustrates a an elevational view of
`the process and machine for converting web pouches to fluid
`filled units; and
`FIG. 9 illustrates a process for converting web pouches to
`fluid filled units.
`
`DETAILED DESCRIPTION
`
`Referring to FIGS. 1 and 2, exemplary illustrations of webs
`10 of inflatable pouches 12 are shown. The webs 10 includes
`
`Page 011
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`US 7,757,459 B2
`
`3
`a top elongated layer of plastic 14 superposed onto a bottom
`layer of plastic 16. The layers are connected together along
`spaced edges, referred to as the inflation edge 18 and the
`opposite edge 20. In the example illustrated by FIG. 1, each
`edge 18, 20 is either a fold or a seal that connects the super(cid:173)
`posed layers 14, 16 along the edges 18, 20. The connection at
`the opposite edge 20 is illustrated as a hermetic seal and the
`connection at the inflation edge 18 is illustrated as a fold in
`FIG. 1. However, the fold and the seal could be reversed or
`both of the connections could be seals in the FIG. 1 embodi- 10
`ment. In the example illustrated by FIG. 2, the inflation edge
`18 comprises a frangible connection 21 and the opposite edge
`20 is a hermetic seal. The illustrated frangible connection 21
`is a line of perforations. The size of the perforations is exag(cid:173)
`gerated to clarifY FIG. 2. The frangible connection 21 may be
`formed by folding the inflation edge 18 and pulling the infla(cid:173)
`tion edge over a serration forming wheel (not shown).
`Referring to FIGS. 1 and 2, a plurality of longitudinally
`spaced, transverse seals 22 join the top and bottom layers 14,
`16. Generally, each transverse seal22 extends from the oppo(cid:173)
`site edge 20 to within a short distance of the inflation edge 18.
`Spaced pairs oflines of perforations 24, 26 extend through the
`top and bottom layers terminating a short distance from the
`edges 18, 20 respectively. A gap forming area 28 extends
`between each associated pair of lines of perforations 24, 26.
`The gap forming area 28 opens to form a gap 13 when the
`pouches are inflated (see FIG. 3).
`A gap forming area 28 denotes an area, preferably linear in
`shape, that will rupture or otherwise separate when exposed
`to a predetermined inflation force. The magnitude of the
`inflation force is less than the magnitude of the force needed
`to rupture or separate the spaced apart lines of perforations
`24, 26. The gap forming area 28 can take on a number of
`embodiments, as will be discussed below. Any method that
`produces an area between the spaced apart lines of perfora- 35
`tions 24, 26 that ruptures or otherwise separates at a force
`lower than a force needed to rupture or separate spaced lines
`of perforations 24, 26 may be employed to make the gap
`forming area 28.
`Referring to FIG. 3, the web 10 of pouches 12 (FIGS.1 and 40
`2) is inflated and sealed to form a row 11 of dunnage units 12'.
`The formed dunnage units 12' are configured to be much
`easier to separate from one another than prior art arrays of
`dunnage units. In the exemplary embodiment of FIG. 3, each
`adjacent pair of dunnage units 12' is connected together by a 45
`pair of spaced apart lines of perforations 24, 26. The spaced
`apart lines of perforations 24, 26 are spaced apart by a gap 13.
`A single row 11 of dunnage units 12' can be graphically
`described as being in a "ladder" configuration. This configu(cid:173)
`ration makes separating two adjacent durmage units 12' much 50
`easier than separating prior art arrays of durmage units. To
`separate a pair of adjacent dunnage units 12, a worker simply
`inserts an object or objects, such as a hand or hands, into the
`gap 13 and pulls one dunnage unit 12' away from the other
`dunnage unit 12'. In the alternative, a mechanical system can 55
`be used to separate durmage units 12'. A machine can be
`configured to insert an object between adjacent dunnage units
`12' and apply a force to separate the units
`Referring to FIGS. 1-3, prior to conversion to a dunnage
`unit, a pouch is typically hermetically sealed on three sides, 60
`leaving one side open to allow for inflation. Once the pouch is
`inflated, the inflation opening is hermetically sealed and the
`dunnage unit is formed. During the inflation process, as the
`volume of the pouch increases the sides of the pouch have a
`tendency to draw inward. Drawing the sides of the pouches 65
`inward will shorten the length of the sides of the pouch unless
`the sides of the pouch are constrained. In this application, the
`
`4
`term foreshortening refers to the tendency of the length of a
`pouch side to shorten as the pouch is inflated. In prior art
`webs, the sides of the pouch are restrained, because sides of
`adjacent pouches are connected by lines of perforations that
`extend along the entire length of the pouches and remain
`intact during and after inflation. The foreshortening of the
`unrestrained sides, such as the inflation opening, may not be
`uniform. Restraining the sides of adjacent connected pouches
`can cause undesirable inflation induced stresses. These unde-
`sirable stresses caused because sides of adjacent pouches are
`connected and restrained, thus, limiting inflation and causing
`wrinkles to develop in the layers at the unrestrained inflation
`opening. The wrinkles can extend into a section of the infla(cid:173)
`tion opening to be sealed to complete the dunnage unit, which
`15 may comprise the seal. One reason the seal can be compro(cid:173)
`mised is that wrinkling can cause sections of the layers 14, 16
`to fold on top of one another. A sealing station of a dunnage
`machine is typically set to apply the appropriate amount of
`heat to seal two layers of material. The sealing of multiple
`20 layers of material in the area of a wrinkle results in a seal that
`is weaker than remaining seal areas and may result in a small
`leak or tendency to rupture at loads lower than loads at which
`the durmage units is designed to rupture.
`In the embodiment illustrated by FIG. 3, the gap forming
`25 area 28, produces a gap 13 between adjacent pouches upon
`inflation. The gap allows foreshortening of the connected
`pouch sides and thereby reduces the undesirable stresses that
`are introduced during inflation as compared with prior art
`webs. In addition, the web with a gap 13 facilitates fuller
`30 inflation of each pouch. The gap 13 maintains the inflation
`opening substantially free of wrinkles as the inflation opening
`is sealed to convert the inflated pouches to a dunnage units.
`The illustrated web 10 is constructed from a heat sealable
`plastic film, such as polyethylene. The web 10 is designed to
`accommodate a process for inflating each pouch 12 in the web
`to create a row or ladder 11 of dunnage units 12'. The gap
`forming area 28 creates a gap 13 between dunnage units 12',
`which facilitate a efficient and effective process for separating
`adjacent durmage units 12' in the row or ladder 11.
`In the example illustrated by FIG. 4, the gap forming area
`28 defined by the web 10' includes an easily breakable line of
`perforations 29 between the spaced lines of perforations 24,
`26. The force needed to rupture or separate the line of perfo(cid:173)
`rations 29 is less than the force needed to separate the perfo(cid:173)
`rations 24, 26 extending inward of the web edges 18, 20. Each
`pair of perforations 24, 26 and associated more easily break-
`able line of perforations 29 divide the transverse seal 22 into
`two transverse sections. As a pouch 12 is inflated, the line of
`perforation 29 begins to rupture or separate leading to the
`development of a gap 13 between the produced dunnage units
`12' (See FIG. 3). Once the pouch 12 is fully inflated, the line
`of perforations 29 is fully or nearly fully ruptured; however
`the perforations 24, 26 at the edges remain intact. These
`perforations 24, 26 are ruptured or separated when a worker
`or automated process mechanically separates the perforations
`24, 26.
`FIG. 5 illustrates another embodiment of the web 10". In
`this embodiment the gap forming area 28 comprises an elon(cid:173)
`gatedcut 31 through both layers ofmaterial14, 16. The cut 31
`extends between each associated pair oflines of perforations
`24, 26. In the embodiment illustrated by FIG. 5, pairs 30 of
`transverse seals 22' extend from the opposite edge 20 to
`within a short distance of the inflation edge 18. Each of the
`pairs oflines of perforations 24, 26 and corresponding cuts 31
`are between an associated pair of transverse seals 30. It should
`be readily apparent that the seal 22 shown in FIG. 4 could be
`used with the cut 31 shown in FIG. 5. It should also be readily
`
`Page 012
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1001
`
`

`
`US 7,757,459 B2
`
`5
`apparent that the line of perforations shown in FIG. 4 could be
`used with the transverse seals 22' shown in FIG. 5. It should be
`additionally apparent that any gap forming area 28 can be
`used with either of the transverse seal configurations 22, 22'
`shown in FIGS. 4 and 5.
`FIG. 6 illustrates a further embodiment of the web 10"'. In
`this embodiment, the gap forming area 28 comprises at least
`two elongated cuts 32, separated by light connections of
`plastic 36, also referred to as "ticks." These connections 36
`hold transverse edges 38, 40 of the pouches 12 together to
`ease handling of the web 10, such as handling required during
`installation of the web 10 into a dunnage machine. As the
`pouches 12 are inflated, the connections 36 rupture or other(cid:173)
`wise break resulting in a gap 13 between the spaced pairs of
`perforations 24, 26. This gap 13 allows for full inflation and
`reduces the stresses in the layers at the seal site normally
`caused by the foreshortening and restrictions on foreshorten(cid:173)
`ing of webs in the prior art. The reduced stress in the layers
`inhibits wrinkles along the inflation opening to be sealed.
`Other methods of creating a gap forming area not specifi(cid:173)
`cally disclosed are with the scope of the present application.
`Any area that separates and forms a gap between adjacent
`pouches as pouches 12 in a web 10 are inflated are contem(cid:173)
`plated by this disclosure.
`FIG. 3, illustrates a length of the web 10, 10', 10" or 10"'
`after it has been inflated and sealed to form dunnage units 12'.
`An inflation seal 42, the transverse seals 22 and an opposite
`edge seal44 hermetically seal the top and bottom layers. The
`side edges 38, 40 of the formed dunnage units are separated to
`form a gap 13. Each pair of adjacent dunnage units 12' are
`connected together by the pair of spaced apart lines of perfo(cid:173)
`rations 24, 26. The gap 13 extends between the pair of spaced
`apart lines of perforations 24, 26. The array of dunnage units
`12' is a single row of dunnage units in a "ladder" configura(cid:173)
`tion. The lines of perforations 24, 26 are configured to be
`easily breakable by a worker or automated system. To sepa(cid:173)
`rate a pair of adjacent units 12', a worker inserts an object,
`such as the worker's hand or hands into the gap 13. The 40
`worker then grasps one or both of the adjacent dunnage units
`12' and pulls the adjacent dunnage units 12' relatively apart as
`indicated by arrows 43a, 43b. The lines of perforation 24, 26
`rupture or otherwise separate and the two adjacent dunnage
`units 12' are separated. The existence of the gap 13 also results
`in reduced stresses in the area of the inflation seal 42 at the
`time of sealing and accommodates increased inflation volume
`of the dunnage units 12' as compared with prior inflated
`dunnage units.
`In one embodiment, the line of perforations 24 that extends
`from the opposite edge 20 is omitted. In this embodiment, the
`gap forming area 28 extends from the inflation edge line of
`perforations 26 to the opposite edge. In this embodiment, the
`gap 13 extends from the inflation edge line of perforations 26
`to the opposite edge 20.
`The connection of the layers 14, 16 at the inflation edge 18
`can be any connection that is maintained between layers 14,
`16 prior to the web 10 being processed to create dunnage units
`12'. In the embodiment illustrated by FIG.1, the connection is
`a fold. In the embodiment illustrated by FIG. 2, the connec(cid:173)
`tion is a line of perforations 21. One method of producing
`such a web is t