Approved for use through 07/3112006. OMB 0651-0032 ct) C')
`U.S. Patent and Trademarl< Office. U.S. DEPARTMENT OF COMMERCE
`·
`Under the Paoerworl< Reduction Act of 1995 no oersons are reouired to respond to a collection of information unless it displavs a valid OMB control number. ::::> ~
`02946/04148
`"' l.!? ,....
`UTILITY
`Attorney Docket No.
`I.C-
`r-----~----------r-----------------------------~~,....
`Rick Steven Wehrmann
`..,... ..-
`PATENT APPLICATION
`First Inventor
`TRANSMITTAL
`
`Title
`
`Web and Method for Making Fluid ...
`
`0
`PTO/SB/05 (04-05) ~ g
`
`(Only for new nonprovisional applications under 37 CFR 1.53(b))
`
`Express Mail Label No. EV 284564891US
`
`APPLICATION ELEMENTS
`See MPEP chapter 600 concerning utility patent application contents.
`
`ADDRESS TO:
`
`Commissioner for Patents
`P.O. Box 1450
`Alexandria VA 22313-1450
`
`1. !Zl
`2.0
`3.0
`
`Fee Transmittal Form (e.g., PTO/SB/17)
`(Submit an original and a duplicate for fee processing)
`Applicant claims small entity status.
`See 37 CFR 1.27.
`17
`Specification
`[Total Pages
`Both the claims and abstract must start on a new page
`(For infonnation on the preferred arrangement, see MPEP 608.01(a))
`Drawing(s) (35 U.S. C. 113)
`7
`[Total Sheets
`
`4. 0
`5. Oath or Declaration
`3
`[Total Sheets
`a. !ZJ Newly executed (original or copy)
`b. D A copy from a prior application (37 CFR 1.63(d))
`___l,for continuation/divisional with Box 18 completed)
`i. U DELETION OF INVENTOR(Sl
`Signed statement attached deleting inventor(s)
`name in the prior application, see 37 CFR
`1 .63(d)(2) and 1.33(b).
`
`6. 0 Application Data Sheet See 37 CFR 1.76
`7. 0
`
`CD-ROM or CD-R in duplicate, large table or
`G.an;Jputer Program {Appendix)
`U Landscape Table on CD
`
`8. Nucleotide and/or Amino Acid Sequence Submission
`(if ape!!.£.able, items a. - c. are required)
`a. U Computer Readable Form (CRF)
`b.
`Specification Sequence Listing on:
`i.D
`ii.O
`
`CD-ROM or CD-R (2 copies); or
`Paper
`
`ACCOMPANYING APPLICATION PARTS
`9. 0 Assignment Papers (cover sheet & document(s))
`Name of Assignee Automated Packaging Systems, Inc.
`
`]
`
`10. D
`
`37 CFR 3.73(b) Statement
`(when there is an assignee)
`
`DPowerof
`Attorney
`
`11. D English Translation Document (if applicable)
`12. D lnfo~tion Disclosure Statement (PTO/SB/08 or PTQ-1449)
`LJ Copies of citations attached
`
`13. D Preliminary Amendment
`14. 0 Return Receipt Postcard (MPEP 503)
`(Should be specifically itemized)
`
`15. D Certified Copy of Priority Document(s)
`(if foreign priority is claimed}
`
`16. D Nonpublication Request under 35 U.S.C. 122(b)(2)(B)(i).
`Applicant must attach form PTO/SB/35 or equivalent.
`17. 0 Other: check in the amount of $2.290.00
`
`Statements verifying identity of above copies
`c. D
`18. If a CONTINUING APPLICATION, check appropriate box, and supply the requisite information below and in the first sentence of the
`specification following the title, or in an Application Data Sheet under 37 CFR 1. 76:
`
`D Continuation
`
`D
`
`Divisional
`
`D Continuation-in-part (CIP)
`
`of prior application No.: ................................ .
`
`Prior application infonnation:
`
`Examiner ____________________ _
`
`Art Unit:---------------------
`
`19. CORRESPONDENCE ADDRESS
`
`[{]The address associated with Customer Number: I
`
`~---------------------~
`
`I
`
`OR D Correspondence address below
`
`Name
`
`Address
`
`City
`Country
`
`Signature
`
`Name
`CPrinUTvoe)
`
`1 State
`1 Telephone
`
`1 Zip Code
`1 Email
`
`Risto Pribisich
`
`Registration No. '1
`55859
`(Attorney/Agent) I
`
`J
`J
`
`This collection of information is required by 37 CFR 1.53(b). The information is required to obtain or retain a benefit by the public which is to file (and by the
`USPTO to process) an application. Confidentiality is governed by 35 U.S.C. 122 and 37 CFR 1.11 and 1.14. This collection is estimated to take 12 minutes to
`complete, induding gathering, preparing, and submitting the completed application form to the USPTO_ Time will vary depending upon the individual case_ Any
`comments on the amount of time you require to complete this form and/or suggestions for reducing this burden, should be sent to the Chief Information Officer.
`U.S. Patent and Trademarl< Off~ee, U.S. Department of Commerce, P.O. Box 1450, Alexandria, VA 22313-1450. DO NOT SEND FEES OR COMPLETED
`FORMS TO THIS ADDRESS. SEND TO: Commissioner for Patents, P.O. Box1450, Alexandria, VA 22313·1450.
`If you need assistance in completing the form, caO 1-IJOO..PTQ-9199 and selecl option 2.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
`
`Page 001
`
`

`
`~
`~
`0
`01=== 0>
`( , . ) -
`
`Effective on 1210812004.
`
`...... == o _
`PTO/SB/17 (12--04v2)
`Approved for use through 0713112006. OMB 0651-0032
`~
`U.S. Patent and Trademarll Office; U.S. DEPARTMENT OF COMMERCE
`01 -
`CllnrtAr thA P"nANtnr1< Rf'!rluctinn Ad nf 1 !'195 nn """""""' '""' r""uimrl tn ,..._<;t)t)lltj tn a r:nllf'!ctinn nf infnrrnminn uniRAA it dL.,nta= " valid OUR r:nntrnl numtv.r
`-
`r-o
`~es pursuant to the Consolidated AD,-optiatiOns Act. 2005 (H.R. 4818,. 1--------.,:..-.:._-------------1
`Complete if Known
`FEE TRANSMITTAL ::~::~;Number
`For FY 2005
`0 Applicant claims small entity status. See 37 CFR 1.27
`2290.00
`"-TOTAL AMOUNT OF PAYMENT I($)
`
`RrstNamedlnventor
`
`Rick Steven Wehrmann
`
`Examiner Name
`
`Art Unit
`
`0294?/0~!48
`
`METHOD OF PAYMENT (check all that apply)
`
`Q Check D Credit Card DMoney Order 0 None OOther (please identify): _ ___,~v-..~--.,.---,...,..----
`03-0172
`Calfee Halter
`Deposit Ao:ount Name: _____________ _
`
`r-1
`~Deposit Account Deposit Account Number:
`For the above-identified deposit account, the Director is hereby authorized to: (check all that apply)
`
`Ocharge fee(s) indicated below
`
`0 Charge fee(s) indicated below. except for the filing fee
`r l Charge any additional fee(s) or underpayments of fee(s) 0 Credit any overpayments
`
`L1'U under 37 CFR 1.16 and 1.17
`WARNING: lnfonnation on this fonn may become public. Credit card infonnatlon should not be Included on this fonn. Provide credit card
`infonnation and authorization on PT0-2038.
`FEE CALCULATION
`
`1. 'BASIC FILING, SEARCH, AND EXAMINATION FEES
`FILING FEES
`SEARCH FEES
`EXAMINATION FEES
`Small Entity
`Small Entltv
`Small Entity
`f.ttiD ~
`.EiLW
`Fee f$)
`150
`500
`250
`100
`100
`100
`50
`65
`300
`80
`100
`150
`500
`300
`150
`250
`0
`iOO
`0
`0
`
`U2.W
`300
`200
`200
`300
`200
`
`fm!.W
`200
`130
`160
`600
`0
`
`Fees Paid ($}
`1000
`
`Application Tvpe
`Utility
`Design
`Plant
`Reissue
`Provisional
`2. EXCESS CLAIM FEES
`Fee Description
`Each claim over 20 (including Reissues)
`Each independent claim over 3 (including Reissues)
`Multiple dependent claims
`Fee ($)
`Total Claims
`Extra Claims
`50 =
`25 -20orHP=
`5
`X
`_H_P_=-hlg_h_es_t number of total daims paid for, if greater !han 20.
`Extra Claims.. ~ Fee Paid f$)
`lndeo. Claims
`:x
`8 - 3 or HP "'
`5
`-----zU"O ::
`1000
`_H_P_=-hig_h_est-number of independent dalms paid for, if greater than 3.
`3. APPLICATION SIZE FEE
`If the specification and drawings exceed 100 sheets of paper (excluding electronically filed sequence or computer
`listings under 37 CFR 1.52(e)), the application size fee due is $250 ($125 for small entity) for each additional 50
`sheets or fraction thereof. See 35 U.S.C. 4Ha)(l)(G) and 37 CFR L 16(s).
`Number of each additional SO or fraction thereof
`Total Sheets
`Extra Sheets
`- - - - - 100 =
`/50=
`(round up to a whole number) x
`4. OTHER FEE(S)
`Non-English Specification, $130 fee (no small entity discount)
`Other (e.g., late filing surcharge):
`
`Sma!l Entity
`.E!!Uil
`~
`25
`50
`200
`100
`360
`180
`Multiple Dependent Claims
`.fu.W
`Fee Paid ($)
`
`Fee Paid ($)
`2SO
`
`f!!!U1l
`
`Fee Paid ($1
`
`=
`
`Fees Paid($)
`
`SUBMITlED BY
`
`I Registration No.
`
`IAt!Dmev/Aaentl
`
`55859
`
`Telephone
`
`(216) 622-8200
`
`Name (Print/Type) Risto Pribisich
`This cdlec:tion of informa1ion is required by 37 CFR 1.136. The information is required to obtain or retain a benefit by the public which is to me (and by the
`USPTO to process) an appfiCStion. Confidentiality is governed by 35 U.S.C. 122 and 37 CFR 1.14. This cdledion is estimated to take 30 minutes to complete,
`induding gathering, preparing, and submitting the cmnpleted application form ID the USPTO. Time wiD vary depending upon the inlfrvidual case. My comments
`on the amount of time you require to complete this form and/or suggestions for reducing this burden. should be sent ID the Chief InformatiOn Officer. U.S. Patent
`and Trademarll Office, U.S. Oepattmentof Commen:e. P.O. Box 1450. Alexandria. VA 22313--1450. DO NOT SENO FEES OR COMPLETED FORMS TO THIS
`ADDRESS. SEND TO: Commissioner for Patents, P.O. Box 1450, Alexandria, VA 22313-1450.
`If you need assistance in completing the form, can 1-800-PT0-9199 and select option 2.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
`
`Page 002
`
`

`
`Approved for use through 07/3112006. OMB 0651-0032 ct) C')
`U.S. Patent and Trademarl< Office. U.S. DEPARTMENT OF COMMERCE
`·
`Under the Paoerworl< Reduction Act of 1995 no oersons are reouired to respond to a collection of information unless it displavs a valid OMB control number. ::::> ~
`02946/04148
`"' l.!? ,....
`UTILITY
`Attorney Docket No.
`I.C-
`r-----~----------r-----------------------------~~,....
`Rick Steven Wehrmann
`..,... ..-
`PATENT APPLICATION
`First Inventor
`TRANSMITTAL
`
`Title
`
`Web and Method for Making Fluid ...
`
`0
`PTO/SB/05 (04-05) ~ g
`
`(Only for new nonprovisional applications under 37 CFR 1.53(b))
`
`Express Mail Label No. EV 284564891US
`
`APPLICATION ELEMENTS
`See MPEP chapter 600 concerning utility patent application contents.
`
`ADDRESS TO:
`
`Commissioner for Patents
`P.O. Box 1450
`Alexandria VA 22313-1450
`
`1. !Zl
`2.0
`3.0
`
`Fee Transmittal Form (e.g., PTO/SB/17)
`(Submit an original and a duplicate for fee processing)
`Applicant claims small entity status.
`See 37 CFR 1.27.
`17
`Specification
`[Total Pages
`Both the claims and abstract must start on a new page
`(For infonnation on the preferred arrangement, see MPEP 608.01(a))
`Drawing(s) (35 U.S. C. 113)
`7
`[Total Sheets
`
`4. 0
`5. Oath or Declaration
`3
`[Total Sheets
`a. !ZJ Newly executed (original or copy)
`b. D A copy from a prior application (37 CFR 1.63(d))
`___l,for continuation/divisional with Box 18 completed)
`i. U DELETION OF INVENTOR(Sl
`Signed statement attached deleting inventor(s)
`name in the prior application, see 37 CFR
`1 .63(d)(2) and 1.33(b).
`
`6. 0 Application Data Sheet See 37 CFR 1.76
`7. 0
`
`CD-ROM or CD-R in duplicate, large table or
`G.an;Jputer Program {Appendix)
`U Landscape Table on CD
`
`8. Nucleotide and/or Amino Acid Sequence Submission
`(if ape!!.£.able, items a. - c. are required)
`a. U Computer Readable Form (CRF)
`b.
`Specification Sequence Listing on:
`i.D
`ii.O
`
`CD-ROM or CD-R (2 copies); or
`Paper
`
`ACCOMPANYING APPLICATION PARTS
`9. 0 Assignment Papers (cover sheet & document(s))
`Name of Assignee Automated Packaging Systems, Inc.
`
`]
`
`10. D
`
`37 CFR 3.73(b) Statement
`(when there is an assignee)
`
`DPowerof
`Attorney
`
`11. D English Translation Document (if applicable)
`12. D lnfo~tion Disclosure Statement (PTO/SB/08 or PTQ-1449)
`LJ Copies of citations attached
`
`13. D Preliminary Amendment
`14. 0 Return Receipt Postcard (MPEP 503)
`(Should be specifically itemized)
`
`15. D Certified Copy of Priority Document(s)
`(if foreign priority is claimed}
`
`16. D Nonpublication Request under 35 U.S.C. 122(b)(2)(B)(i).
`Applicant must attach form PTO/SB/35 or equivalent.
`17. 0 Other: check in the amount of $2.290.00
`
`Statements verifying identity of above copies
`c. D
`18. If a CONTINUING APPLICATION, check appropriate box, and supply the requisite information below and in the first sentence of the
`specification following the title, or in an Application Data Sheet under 37 CFR 1. 76:
`
`D Continuation
`
`D
`
`Divisional
`
`D Continuation-in-part (CIP)
`
`of prior application No.: ................................ .
`
`Prior application infonnation:
`
`Examiner ____________________ _
`
`Art Unit:---------------------
`
`19. CORRESPONDENCE ADDRESS
`
`[{]The address associated with Customer Number: I
`
`~---------------------~
`
`I
`
`OR D Correspondence address below
`
`Name
`
`Address
`
`City
`Country
`
`Signature
`
`Name
`CPrinUTvoe)
`
`1 State
`1 Telephone
`
`1 Zip Code
`1 Email
`
`Risto Pribisich
`
`Registration No. '1
`55859
`(Attorney/Agent) I
`
`J
`J
`
`This collection of information is required by 37 CFR 1.53(b). The information is required to obtain or retain a benefit by the public which is to file (and by the
`USPTO to process) an application. Confidentiality is governed by 35 U.S.C. 122 and 37 CFR 1.11 and 1.14. This collection is estimated to take 12 minutes to
`complete, induding gathering, preparing, and submitting the completed application form to the USPTO_ Time will vary depending upon the individual case_ Any
`comments on the amount of time you require to complete this form and/or suggestions for reducing this burden, should be sent to the Chief Information Officer.
`U.S. Patent and Trademarl< Off~ee, U.S. Department of Commerce, P.O. Box 1450, Alexandria, VA 22313-1450. DO NOT SEND FEES OR COMPLETED
`FORMS TO THIS ADDRESS. SEND TO: Commissioner for Patents, P.O. Box1450, Alexandria, VA 22313·1450.
`If you need assistance in completing the form, caO 1-IJOO..PTQ-9199 and selecl option 2.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
`
`Page 003
`
`

`
`~
`~
`0
`01=== 0>
`( , . ) -
`
`Effective on 1210812004.
`
`...... == o _
`PTO/SB/17 (12--04v2)
`Approved for use through 0713112006. OMB 0651-0032
`~
`U.S. Patent and Trademarll Office; U.S. DEPARTMENT OF COMMERCE
`01 -
`CllnrtAr thA P"nANtnr1< Rf'!rluctinn Ad nf 1 !'195 nn """""""' '""' r""uimrl tn ,..._<;t)t)lltj tn a r:nllf'!ctinn nf infnrrnminn uniRAA it dL.,nta= " valid OUR r:nntrnl numtv.r
`-
`r-o
`~es pursuant to the Consolidated AD,-optiatiOns Act. 2005 (H.R. 4818,. 1--------.,:..-.:._-------------1
`Complete if Known
`FEE TRANSMITTAL ::~::~;Number
`For FY 2005
`0 Applicant claims small entity status. See 37 CFR 1.27
`2290.00
`"-TOTAL AMOUNT OF PAYMENT I($)
`
`RrstNamedlnventor
`
`Rick Steven Wehrmann
`
`Examiner Name
`
`Art Unit
`
`0294?/0~!48
`
`METHOD OF PAYMENT (check all that apply)
`
`Q Check D Credit Card DMoney Order 0 None OOther (please identify): _ ___,~v-..~--.,.---,...,..----
`03-0172
`Calfee Halter
`Deposit Ao:ount Name: _____________ _
`
`r-1
`~Deposit Account Deposit Account Number:
`For the above-identified deposit account, the Director is hereby authorized to: (check all that apply)
`
`Ocharge fee(s) indicated below
`
`0 Charge fee(s) indicated below. except for the filing fee
`r l Charge any additional fee(s) or underpayments of fee(s) 0 Credit any overpayments
`
`L1'U under 37 CFR 1.16 and 1.17
`WARNING: lnfonnation on this fonn may become public. Credit card infonnatlon should not be Included on this fonn. Provide credit card
`infonnation and authorization on PT0-2038.
`FEE CALCULATION
`
`1. 'BASIC FILING, SEARCH, AND EXAMINATION FEES
`FILING FEES
`SEARCH FEES
`EXAMINATION FEES
`Small Entity
`Small Entltv
`Small Entity
`f.ttiD ~
`.EiLW
`Fee f$)
`150
`500
`250
`100
`100
`100
`50
`65
`300
`80
`100
`150
`500
`300
`150
`250
`0
`iOO
`0
`0
`
`U2.W
`300
`200
`200
`300
`200
`
`fm!.W
`200
`130
`160
`600
`0
`
`Fees Paid ($}
`1000
`
`Application Tvpe
`Utility
`Design
`Plant
`Reissue
`Provisional
`2. EXCESS CLAIM FEES
`Fee Description
`Each claim over 20 (including Reissues)
`Each independent claim over 3 (including Reissues)
`Multiple dependent claims
`Fee ($)
`Total Claims
`Extra Claims
`50 =
`25 -20orHP=
`5
`X
`_H_P_=-hlg_h_es_t number of total daims paid for, if greater !han 20.
`Extra Claims.. ~ Fee Paid f$)
`lndeo. Claims
`:x
`8 - 3 or HP "'
`5
`-----zU"O ::
`1000
`_H_P_=-hig_h_est-number of independent dalms paid for, if greater than 3.
`3. APPLICATION SIZE FEE
`If the specification and drawings exceed 100 sheets of paper (excluding electronically filed sequence or computer
`listings under 37 CFR 1.52(e)), the application size fee due is $250 ($125 for small entity) for each additional 50
`sheets or fraction thereof. See 35 U.S.C. 4Ha)(l)(G) and 37 CFR L 16(s).
`Number of each additional SO or fraction thereof
`Total Sheets
`Extra Sheets
`- - - - - 100 =
`/50=
`(round up to a whole number) x
`4. OTHER FEE(S)
`Non-English Specification, $130 fee (no small entity discount)
`Other (e.g., late filing surcharge):
`
`Sma!l Entity
`.E!!Uil
`~
`25
`50
`200
`100
`360
`180
`Multiple Dependent Claims
`.fu.W
`Fee Paid ($)
`
`Fee Paid ($)
`2SO
`
`f!!!U1l
`
`Fee Paid ($1
`
`=
`
`Fees Paid($)
`
`SUBMITlED BY
`
`I Registration No.
`
`IAt!Dmev/Aaentl
`
`55859
`
`Telephone
`
`(216) 622-8200
`
`Name (Print/Type) Risto Pribisich
`This cdlec:tion of informa1ion is required by 37 CFR 1.136. The information is required to obtain or retain a benefit by the public which is to me (and by the
`USPTO to process) an appfiCStion. Confidentiality is governed by 35 U.S.C. 122 and 37 CFR 1.14. This cdledion is estimated to take 30 minutes to complete,
`induding gathering, preparing, and submitting the cmnpleted application form ID the USPTO. Time wiD vary depending upon the inlfrvidual case. My comments
`on the amount of time you require to complete this form and/or suggestions for reducing this burden. should be sent ID the Chief InformatiOn Officer. U.S. Patent
`and Trademarll Office, U.S. Oepattmentof Commen:e. P.O. Box 1450. Alexandria. VA 22313--1450. DO NOT SENO FEES OR COMPLETED FORMS TO THIS
`ADDRESS. SEND TO: Commissioner for Patents, P.O. Box 1450, Alexandria, VA 22313-1450.
`If you need assistance in completing the form, can 1-800-PT0-9199 and select option 2.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
`
`Page 004
`
`

`
`"EXPRESS MAIL" Mailing Label No.:{;_ V ~ '9 '-/ ~- (, 1/ }J C1 ( (,( .S
`Date of Deposit: 5- 1 1 • ~ 0 o (
`I hereby certify that this paper or fee is being deposited with
`the United States Postal Service "Express Mail Post Office to
`Addressee" service under 37 CFR 1.10 on the date indicated
`above and is addressed to the Commissioner for Patents,
`P.O.~ 1450, Alexandria, VA 22313·1450.
`
`" o B ££ r 1t111U:S
`Signed~./~
`
`Name oNS1gni~ype or P~
`
`02946/04148
`
`Customer Number
`
`24024
`
`Web and Method for Making Fluid Filled Units
`
`Relate Back
`
`The present application claims priority from provisional patent applications serial
`
`numbers 60/576,004, entitled "Web for Fluid Filled Unit Formation,". filed on June 1,
`
`2004, and provisional patent application serial number 60/592,812, entitled "Air Pouch
`
`Machine," filed on July 30, 2004. Provisional patent applications serial numbers
`
`60/576,004 and 60/592,812 are incorporated herein by reference in their entirety.
`
`Field of the Invention
`
`The present application relates to fluid filled units and more pat-ticularly 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 dunnage 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 perforations. 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.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
`
`Page 005
`
`

`
`Summary
`
`The present invention relates to plastic webs of interconnected pouches and
`
`processes of converting interconnected pouches to at least one row of dunnage units. In
`
`one embodiment, 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 preformed 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 newly formed and adjacent dunnage units. In one
`
`embodiment, the gap runs between an inflation edge line of perforations and a spaced
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`apart opposite edge line of perforations. Pouches are converted to dunnage units by
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`inflating the pouch with a fluid, substantially maintaining the inflated volume of the
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`pouch, and hermetically sealing an inflated pouch.
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`The gap between the inflation edge line of perforations and the spaced apart
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`opposite edge line of perforations makes separating the dunnage units much simpler and
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`easier than separating dunnage units that are connected by a continuous line of un(cid:173)
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`ruptured perforations. In the present invention, to separate adjacent dunnage units, a
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`worker simply inserts a hand or hari.ds into the gap between adjacent dunnage units and
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`applies forces on one or both of the dunnage units, which are connected only by the
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`spaced apart lines of perforations. As the spaced apart lines of perforations rupture or
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`otherwise separate the adjacent dunnage units are separated.
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`In one embodiment, an inflated volume is maintained in each air pouch by
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`blowing air into an inflation opening of each pouch until substantially the entire inflation
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`opening of the pouch is sealed. In one embodiment, the inflation opening is closed at a
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`closing location located along the web path of travel. Air is provided into each pouch
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`from a position slightly upstream ofthe closing location to maintain inflation of the
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`pouch until it is sealed. For example, the inflation is maintained by blowing air into the
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`2
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`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
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`Page 006
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`inflation opening until the a trailing transverse seal of the pouch is within 0.250 inches of
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`the closing position.
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`In one embodiment, inflated dunnage unit arrays comprise a single row of
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`interconnected inflated pouches. The pouches are defined by first and second layers
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`connected together at an inflation edge, an opposite edge seal, and by a pair of seals that
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`are generally transverse to the inflation edge and the opposite edge. Each pair of adjacent
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`inflated pouches are connected by an inflation edge line of perforations that extends
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`inward and generally perpendicular to the inflation edge and an opposite edge line of
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`perforations that extends inward and generally perpendicular to the opposite edge. The
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`inflation edge line of perforations and the opposite edge line of perforations are spaced
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`apart by a gap that allows a worker to insert an object, such as a hand, to easily separate
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`the pair of adjacent inflated dunnage units.
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`In one embodiment, a web for forming dunnage units comprises a first elongated
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`layer and a second elongated layer superposed over the first elongated layer. The first
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`and second layers are connected by a frangible connection that extends along an inflation
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`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
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`of transverse seals extend from the hermetic seal to within a predetermined distance from
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`the frangible connection. The hermetic seal and said transverse seals form a plurality of
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`inflatable pouches.
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`Further advantages and benefits will become apparent to those skilled in the art
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`after considering the following description and appended claims in conjunction with the
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`accompanying drawings.
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`Brief Description of the Drawings
`
`Figure 1 illustrates a web for making fluid filled units;
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`Figure 2 illustrates a web for making fluid filled units;
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`Figure 3 illustrates a web with pouches inflated and sealed to form fluid filled
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`units;
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`Figure 4 illustrates a web for making fluid filled units;
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`Figure 5 illustrates a web for making fluid filled units;
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`3
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`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
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`Page 007
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`Figure 6 illustrates a web for making fluid filled units;
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`Figure 7 A schematically illustrates a plan view of a process and machine for
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`converting web pouches to fluid filled units;
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`Figure 7B schematically illustrates a plan view of a process and machine for
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`converting web pouches to ·fluid filled units;
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`Figure SA schematically illustrates an elevational view of the process and
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`machine for converting web pouches to fluid filled units;
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`Figure SB schematically illustrates a an elevational view of the process and
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`machine for converting web pouches to fluid filled units; and
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`Figure 9 illustrates a process for converting web pouches to fluid filled units.
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`Detailed Description
`
`Referring to Figures 1 and 2, exemplary illustrations of webs 10 of inflatable
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`pouches 12 are shown. The webs 10 includes a top elongated layer of plastic 14
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`superposed onto a bottom layer of plastic 16. The layers are connected together along
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`spaced edges, referred to as the inflation edge 18 and the opposite edge 20. In the
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`example illustrated by Figure 1, each edge 18, 20 is either a fold or a seal that connects
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`the superposed layers 14, 16 along the edges 18, 20. The connection at the opposite edge
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`20 is illustrated as a hermetic seal and the connection at the inflation edge 18 is illustrated
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`as a fold in Figure 1. However, the fold and the seal could be reversed or both of the
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`connections could be seals in the Figure 1 embodiment. In the example illustrated by
`
`Figure 2, the inflation edge 18 comprises a frangible connection 21 and the opposite edge
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`20 is a hermetic seal. The illustrated frangible connection 21 is a line of perforations.
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`The size of the perforations is exaggerated to clarify Figure 2. The frangible connection
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`21 may be formed by folding the inflation edge 18 and pulling the inflation edge over a
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`serration forming wheel (not shown).
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`Referring to Figures 1 and 2, a plurality oflongitudinally spaced, transverse seals
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`22 join the top and bottom layers 14, 16. Generally, each transverse sea122 extends from
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`the opposite edge 20 to within a short distance of the inflation edge 18. Spaced pairs of
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`lines 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
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`4
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`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
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`Page 008
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`each associated pair of lines of perforations 24, 26. The gap forming area 28 opens to
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`form a gap 13 when the pouches are inflated (see Figure 3).
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`A gap forming area 28 denotes an area, preferably linear in shape, that will
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`rupture or otherwise separate when exposed to a predetermined inflation force. The
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`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
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`take on a number of embodiments, as will be discussed below. Any method that
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`produces an area between the spaced apart lines of perforations 24, 26 that ruptures or
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`otherwise separates at a force lower than a force needed to rupture or separate spaced
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`lines of perforations 24, 26 may be employed to make the gap forming area 28.
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`Referring to Figure 3, the web 10 of pouches 12 (Figures 1 and 2) is inflated and
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`sealed to form a row 11 of dunnage units 12'. The formed dunnage units 12' are
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`configured to be much easier to separate from one another than prior art arrays of
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`dunnage units. In the exemplary embodiment of Figure 3, each adjacent pair of dunnage
`
`units 12' is connected together by a pair of spaced apart lines of perforations 24, 26. The
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`spaced apart lines of perforations 24, 26 are spaced apart by a gap 13. A single row 11 of
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`dunnage units 12' can be graphically described as being in a "ladder" configuration. This
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`configuration makes separating two adjacent dunnage units 12' much easier than
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`separating prior art arrays of dunnage 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
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`and pulls one dunnage unit 12' away from the other dunnage unit 12'. In the alternative,
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`a mechanical system can be used to separate dunnage units 12'. A machine can be
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`configured to insert an object between adjacent dunnage units 12' and apply a force to
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`separate the units
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`Referring to Figures 1-3, prior to conversion to a dunnage unit, a pouch is
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`typically hermetically sealed on three sides, leaving one side open to allow for inflation.
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`Once the pouch is inflated, the inflation opening is hermetically sealed and the dunnage
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`unit is formed. During the inflation process, as the volume of the pouch increases the
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`sides of the pouch have a tendency to draw inward. Drawing the sides of the pouches
`
`inward will shorten the length of the sides of the pouch unless the sides of the pouch are
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`constrained. In this application, the term foreshortening refers to the tendency of the
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`5
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`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
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`Page 009
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`length of a pouch side to shorten as the pouch is inflated. In prior art webs, the sides of
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`the pouch are restrained, because sides of adjacent pouches are connected by lines of
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`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
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`opening, may not be uniform. Restraining the sides of adjacent connected pouches can
`
`cause undesirable inflation induced stresses. These undesirable stresses caused because
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`sides of adjacent pouches are connected and restrained, thus, limiting inflation and
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`causing wrinkles to develop in the layers at the unrestrained inflation opening. The
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`wrinkles can extend into a section of the inflation opening to be sealed to complete the
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`dunnage unit, which may comprise the seal. One reason the seal can be compromised is
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`that wrinkling can cause sections ofthe layers 14, 16 to fold on top of one another. A
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`sealing station of a dunnage machine is typically set to apply the appropriate amount of
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`heat to seal two layers of material. The sealing of multiple 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
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`small leak or tendency to rupture at loads lower than loads at which the dunnage units is
`
`designed to rupture.
`
`In the embodiment illustrated by Figure 3, the gap forming area 28, produces a
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`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 inflation of each pouch. The gap 13 maintains the inflation opening
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`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
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`polyethylene. The web 10 is designed to accommodate a process for inflating each pouch
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`12 in the web to create a row or ladder 11 of dunnage units 12'. The gap forming area 28
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`creates a gap 13 between dunnage units 12 ', which facilitate a efficient and effective
`
`process for separating adjacent dunnage units 12' in the row or ladder 11.
`In the example illustrated by Figure 4, the gap forming area 28 defined by the web
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`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 perforations 29 is
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`6
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`Free-Flow Packaging Int'l, Inc.
`Exhibit 1002
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`Page 010
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`less than the force needed to separate the perforations 24, 26 extending inward of the web
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`edges 18, 20. Each pair of perforations 24, 26 and associated more easily breakable 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 Figure 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