(19) United States
`(12) Patent Application Publication (10) Pub. N0.: US 2001/0013215 A1
`Fuss et al.
`(43) Pub. Date:
`Aug. 16, 2001
`
`US 20010013215A1
`
`(54) SYSTEM, METHOD AND MATERIAL FOR
`MAKING PNEUMATICALLY FILLED
`PACKING CUSHIONS
`
`(76) Inventors: Gunter G. Fuss, San Mateo, CA (US);
`Vladimir Yampolsky, San Carlos, CA
`(Us)
`
`'
`lclgrreslgngdeafé Ahidress'
`FLVEVE‘R lioHléicH TEST
`ALBRITON & HERBERT LLP
`Suite 3400’ four Embarcadero Center
`San Francisco’ CA 94111 (Us)
`
`(21) Appl. No.:
`
`09/765,064
`
`(22) F?edi
`
`Jall- 17, 2001
`_
`_
`Related U‘S‘ Apphcatlon Data
`(63) Continuationdnmart of application NO‘ 09/488,622,
`?led on Jan 20 2000
`'
`’
`'
`publication Classi?cation
`
`(51) Int. Cl.7 ..................................................... .. B65B 9/02
`
`(52) US. Cl. .................. .. 53/403; 53/459; 53/79; 53/553
`
`57
`(
`)
`
`ABSTRACT
`
`System, method and material for making pneumatically
`?lled packing cushions in Which a plastic ?lm material
`having tWo superposed layers joined together along ?rst and
`second longitudinal edges is prefabricated at a ?rst location
`by forming longitudinally spaced, transversely extending
`rows 'of perforations across it and sealing it together along
`seal lines WhlCh extend from the ?rst edge of the material in
`a direction generally parallel to the roWs of perforations
`other and terminate a short distance from the second edge to
`form chambers With open mouths facing the second edge
`betWeen the roWs of perforations. The material is then
`fan-folded or formed into rolls for storage and shipment. At
`a second location, gas is introduced into the chambers by
`passing the material along a tube positioned between the
`ends of the seals and the second edge of the material and
`injecting the gas into the open mouths of the chambers
`through openings in a side Wall of the tube. The tWo layers
`are then sealed together across the open mouths to close the
`chambers and retain the gas in them.
`
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`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 001
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 1 0f 12
`
`US 2001/0013215 A1
`
`_ _ _ _ _ _ _ _ _ _ _ _
`
`—___——_a______
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 002
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 2 0f 12
`
`US 2001/0013215 A1
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 003
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 3 0f 12
`
`US 2001/0013215 A1
`
`\ \
`____ __
`
`E r z
`
`LP
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 004
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 4 0f 12
`
`US 2001/0013215 A1
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 005
`
`

`
`US 2001/0013215 A1
`
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`
`Patent Application Publication Aug. 16, 2001 Sheet 5 0f 12
`
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`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 006
`
`

`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 007
`
`

`
`ent Application Publicati 0 n A u . 1 6 2 0 0 1 S h e e t 7 0 f 12
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 008
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 8 0f 12
`
`US 2001/0013215 A1
`
`
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`
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`2 3 16D‘
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 009
`
`

`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 010
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 10 0f 12
`
`US 2001/0013215 A1
`
`Q lgk
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 011
`
`

`
`Patent Application Publication Aug. 16, 2001 Sheet 11 0f 12
`
`US 2001/0013215 A1
`
`9 I91.‘
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 012
`
`

`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 013
`
`

`
`US 2001/0013215 A1
`
`Aug. 16, 2001
`
`SYSTEM, METHOD AND MATERIAL FOR
`MAKING PNEUMATICALLY FILLED PACKING
`CUSHIONS
`
`[0010] FIG. 1 is top plan vieW, partly broken aWay, of one
`embodiment of a material for use in making pneumatically
`?lled packing cushions in accordance With the invention.
`
`[0001] This is a continuation-in-part of Ser. No. 09/488,
`622, ?led Jan. 20, 2000.
`[0002] This invention pertains generally to packing mate
`rials and, more particularly, to a system, method and mate
`rial for making pneumatically ?lled packing cushions.
`
`[0003] Air ?lled pilloWs or cushions are currently used as
`a packing material and void ?ller in shipping cartons and the
`like. Such cushions typically have of tWo layers of plastic
`?lm material Which are sealed together to form chambers
`that are ?lled With air. The cushions are usually made in
`continuous strings, With perforations betWeen successive
`ones of the cushions for tearing them apart.
`
`[0004] In order to reduce the amount of space required for
`shipment and storage, these air ?lled cushions are generally
`made at or near the point of use. Forming the perforations
`and seals and ?lling the cushions requires relatively com
`plicated and expensive machines, and also requires a packer
`or shipper to undertake a more substantial manufacturing
`operation than he may Want to.
`
`[0005] Heretofore, there have been some attempts to
`reduce the complexity and cost of the machine Which the
`packer or shipper must have by forming the perforations and
`some of the seals in the ?lm material before it is shipped to
`him. Examples of such prefabricated materials are found in
`Ser. No. 09/488,621, ?led Jan. 20, 2000. While those mate
`rials do permit simpler and less expensive machines to be
`used, there are still problems of getting the air into the
`cushions and getting the material sealed Without losing the
`air so that the cushions Will be in?ated in a uniform and
`controllable manner.
`
`[0006] It is in general an object of the invention to provide
`a neW and improved system, method and material for
`making pneumatically ?lled packing cushions.
`[0007] Another object of the invention is to provide a
`system, method and material of the above character Which
`overcomes the limitations and disadvantages of the prior art.
`
`[0008] These and other objects are achieved in accordance
`With the invention by providing a system, method and
`material for making pneumatically ?lled packing cushions in
`Which a plastic ?lm material having tWo superposed layers
`joined together along ?rst and second longitudinal edges is
`processed at a ?rst location by forming longitudinally
`spaced, transversely extending roWs of perforations across it
`and sealing the tWo layers together along seal lines Which
`extend from the ?rst edge of the material in a direction
`generally parallel to the roWs of perforations and terminate
`a short distance from the second edge of the material to form
`chambers With open mouths facing the second edge betWeen
`the roWs of perforations. The material is then fan-folded or
`formed into rolls for storage and shipment.
`
`[0009] At a second location, gas is introduced into the
`chambers by passing the material along a tube positioned
`betWeen the ends of the seals and the second edge of the
`material and injecting the gas into the open mouths of the
`chambers through openings in a side Wall of the tube. The
`tWo layers are then sealed together across the open mouths
`to close the chambers and retain the gas in them.
`
`[0011] FIG. 2 is an isometric vieW of one embodiment of
`a machine for making the material of FIG. 1.
`
`[0012] FIG. 3 is an isometric vieW of the underside of the
`platen or die used in the machine of FIG. 2.
`
`[0013] FIG. 4 is side elevational vieW of one embodiment
`of a machine for making packing cushions in accordance
`With the invention.
`
`[0014] FIG. 5 is a cross-sectional vieW taken along line
`5-5 in FIG. 4.
`
`[0015] FIG. 6 is an operational vieWs of the embodiment
`of FIG. 4.
`
`[0016] FIGS. 7 and 8 are fragmentary top plan vieWs,
`partly broken aWay, of other embodiments of material for
`use in making pneumatically ?lled packing cushions in
`accordance With the invention.
`
`[0017] FIG. 9 is an isometric vieW of another embodiment
`of a machine for making packing cushions in accordance
`With the invention.
`
`[0018] FIG. 10 is a fragmentary, isometric vieW of the
`knife for slitting the ?lm material for separation from the
`in?ation tube in the embodiment of FIG. 9.
`
`[0019] FIG. 11 is an isometric vieW similar to FIG. 9 With
`the covers removed from the machine.
`
`[0020] FIGS. 12-15 are isometric vieWs of the embodi
`ment of FIG. 9 With the covers and different modules
`removed from the machine.
`
`[0021] FIG. 16 is an isometric vieW of another embodi
`ment of a machine for making packing cushions in accor
`dance With the invention.
`
`[0022] As illustrated in FIG. 1, the material for making
`the pneumatically in?ated cushions consists of an elongated
`length of ?attened plastic tubing 11 having an upper layer 12
`and a loWer layer 13. The material can be any suitable plastic
`?lm, such as high density polyethylene. This material is
`joined together, or closed, along its tWo longitudinal edges
`16, 17.
`[0023] Transversely extending roWs of perforations 19 are
`formed across the tubing at longitudinally spaced intervals
`along the length of the tubing. These perforations separate
`adjacent ones of the cushions and provide means for tearing
`the cushions apart.
`
`[0024] BetWeen each of the roWs of perforations, the tWo
`layers of ?lm material are sealed together along a pair of
`lines 22, 23 Which de?ne chambers 24 Which are ultimately
`?lled With air or other suitable gas to form the cushions.
`Each of the seal lines includes a relatively long ?rst segment
`22a, 23a Which extends from edge 16 in a direction gener
`ally parallel to the roWs of perforations and in proximity to
`the them. The length of those segments is on the order of 85
`to 90 percent of the Width of the material. As the lines
`approach edge 17, they turn toWard each other With longi
`tudinally extending segments 22b, 23b Which have a length
`equal to about one-third of the distance betWeen the roWs of
`perforations. The lines then turn toWard edge 17 again With
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 014
`
`

`
`US 2001/0013215 A1
`
`Aug. 16, 2001
`
`segments 22c, 23c Which terminate a short distance from
`that edge. The corners betWeen the different segments are
`rounded, and the chambers de?ned by these lines have a
`shape similar to a conventional hot Water bottle, With a
`relatively narroW open mouth 25 facing toWard edge 17.
`
`material, it can accommodate materials of different Widths.
`As discussed more fully hereinafter, rollers 44 turn slightly
`sloWer than rollers 43 so that the mouths of the chambers
`tend to open up, rather than being draWn taut, as they pass
`betWeen the rollers.
`
`[0025] In one embodiment made from plastic tubing hav
`ing a ?attened Width of 9 inches, the roWs of perforations are
`spaced about 4-3/s inches apart, the seal lines are about Vs
`inch Wide, segments 22a, 23a are spaced about Vs inch from
`the perforations, and the mouths of the chambers are about
`% inch Wide and spaced about 7/16 inch from the edge of the
`material.
`
`[0026] After the perforations and the seals are formed, the
`material is Wound onto a roll 26 for shipment and storage.
`
`[0027] In the system shoWn in FIG. 2, perforations 19 and
`seals 22, 23 are formed by a knife 27 and a heated die or
`platen 28. The knife has a plurality of triangular teeth 29
`Which cut the perforations, and the platen has die elements
`31, 32 on its under face for heating the material to form the
`seals. In this particular embodiment, the platen is Wider than
`the material, and the long segments 31a, 32a of the die
`elements eXtend beyond the edge 16 of the material, With
`that edge closing off the ends of the chambers. Alternatively,
`if desired, the platen can be made narroWer than the material,
`With an additional die segment for sealing the material along
`a line spaced in a short distance from edge 16 to close that
`end of the chambers.
`
`[0028] The platen has a body of metal or other suitable
`heat conductive material, and is heated by a electric heaters
`34 mounted in bores 35 in the body.
`
`[0029] The knife is mounted in a ?xed position on one side
`of platen, and can be insulated from the platen by ceramic
`spacers (not shoWn) to reduce heat transfer to the knife. The
`platen and knife are mounted on the reciprocating head of a
`machine 36 for engagement With the ?lm material as the
`material is fed beneath the head. Abrush 37 is mounted on
`the bed of the machine beneath the knife for supporting the
`?lm material as the perforations are cut.
`
`[0030] Although only one platen and one knife are
`employed in this particular machine, it is contemplated that
`machines for making the material Will have a plurality of
`platens and knives for forming the seal lines and perfora
`tions for a plurality of cushions on each stroke. Alternatively,
`if desired, the seals can be formed With a rotary die having
`one or more die elements spaced around its circumference,
`With knives betWeen them.
`
`[0031] At the location Where the cushions are to be
`completed and used, a machine 38 is provided for injecting
`air or another suitable gas into chambers 24 through the open
`mouths 25, then sealing the mouths shut to con?ne the gas
`Within the chambers.
`
`[0032] As illustrated in FIGS. 4 and 5, the machine has a
`horiZontally extending bed 39 on Which the material rests as
`it passes through the machine. It also has a frame in the form
`of an upstanding plate 41 at the rear of the bed, With feet 42
`supporting the bed toWard the front. TWo pairs of feed rollers
`43, 44 are mounted on the plate for draWing the material
`from rolls 26 and feeding it through the machine. The feed
`rollers engage the material a short distance in from edge 17.
`Since the machine engages only the one edge portion of the
`
`[0033] An in?ation tube 46 eXtends longitudinally near
`frame plate 41 in the path of the material passing through the
`machine. One end of the tube is connected to a source of air
`or other suitable gas (not shoWn), and the other end is
`supported loosely betWeen a pair of grooved rollers 47
`Which are rotatively mounted on the base plate. Aplurality
`of openings 48 are provided in the side Wall of the tube
`betWeen the feed rollers for injecting the air or other gas into
`the chambers. As the material is fed into the machine, the
`free end of the in?ation tube enters the passageWay betWeen
`the ends of seals 22, 23 and the edge 17 of the material. The
`tube thus serves as a guide for the material as Well as the
`means for in?ating the cushions. The ?t betWeen the guide
`rollers and the tube is such that the material can pass freely
`betWeen them, but the rollers still provide support for the
`free end of the tube.
`
`[0034] The air or gas is introduced at a pressure on the
`order of 3 psi, Which can be provided by a small pump (not
`shoWn), or if the machine is pneumatically operated, it can
`be derived from the compressed air source for the machine.
`
`[0035] Means is provided for sealing the open mouths of
`the chambers after the air has been introduced. In the
`embodiment illustrated, this means comprises a belt sealer
`49 Which has a pair traveling belts 51 that carry the ?lm
`material past heater blocks 52 positioned on opposite sides
`of the material. In one present embodiment, belts are made
`of Te?on®, Which can Withstand the heat and transfer it from
`the blocks to the ?lm material. The sealer also has a pair of
`cooling blocks 53 positioned doWnstream of the heater
`blocks. The heater blocks and cooling blocks are urged
`together by springs 54, Which ensures good contact betWeen
`the blocks and the belts and betWeen the belts and the ?lm
`material.
`
`[0036] A knurling Wheel 56 is provided for knurling the
`Warm material leaving the sealer. This Wheel is rotatively
`driven and is urged against an idler Wheel 57 by a spring 58.
`
`[0037] A knife 59 is mounted on the base plate after the
`knurling Wheel for slitting the material along edge 17 so it
`can pass over the in?ation tube Which turns rearWardly at
`that point.
`
`[0038] The drive mechanism is located behind plate 41
`and is of conventional design. It is omitted from the draW
`ings for ease and clarity of illustration.
`
`[0039] Operation and use of the system, and therein the
`method of the invention are as folloWs. The ?lm material is
`perforated and sealed at one location to form the chambers
`With the relatively narroW open mouths, then Wound onto
`rolls for shipment and storage. At the location Where the
`cushions are to be completed and used, the material is draWn
`from a roll by feed rollers 43, 44 and fed along in?ation tube
`46. With rollers 44 turning slightly sloWer than rollers 43,
`the mouths of the chambers tend to open up as they pass
`betWeen the rollers, and the air or gas is injected into the
`chambers 24 through the open mouths from the openings 48
`in the in?ation tube.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 015
`
`

`
`US 2001/0013215 A1
`
`Aug. 16, 2001
`
`[0040] Immediately after the air or gas is injected, the
`mouths of the chambers are sealed shut by the sealing unit
`49 and knurling Wheel 56. Because of the relatively narrow
`mouths, little if any air escapes from the chambers before
`they are sealed, and the resulting cushions therefore tend to
`be ?lled quite uniformly. As the material leaves the machine,
`it is slit along edge 17 by knife 59 to free it from the in?ation
`tube.
`
`[0041] FIG. 6 shoWs the material 11 being fed into the
`machine, With air being injected into chambers 24 and the
`cushions advancing to the sealer after the chambers have
`been ?lled.
`
`[0042] FIG. 7 illustrates an embodiment in Which a Wider
`?lm material is prepared for use in making tWo strings of
`cushions. In this embodiment, tWo layers of material 61, 62
`are joined together along their edges 63, 64, and a slit seal
`66 is formed doWn the center of the material. Transverse
`roWs of perforations 67 are formed across the entire Width of
`the material, and seals 68 are formed on either side of the slit
`seal to de?ne the chambers 69 for the cushions.
`
`[0043] As in the embodiment of FIG. 1, the chambers
`have relatively narroW open mouths 71, but seals 68 differ
`from the seals 22, 23 in that they extend across the loWer
`edges 72 of the chambers instead of running off the edge of
`the material.
`
`[0044] In use, the tWo halves of the material are separated
`and fed though a machine Which injects the air and seals the
`chambers in the manner described above With regard to the
`material of FIG. 1. If desired, the tWo halves can be Wound
`onto a single roll and separated at the point of use, or they
`can be separated at the point of manufacture and Wound onto
`separate rolls.
`
`[0045] In the embodiment of FIG. 8, the material 73 once
`again comprises an elongated length of ?attened plastic
`tubing 74, With roWs of perforations 76 extending trans
`versely across the tubing from one edge to the other.
`
`[0046] BetWeen the roWs of perforations, the tWo layers
`77, 78 of the ?attened tubing are sealed together along
`straight lines 79, 81. These seals extend transversely from
`one edge 82 of the tubing toWard the other and terminate a
`short distance from the second edge 83. Each pair of seal
`lines 79, 81 de?nes an air chamber 84 Which has an open
`mouth 86 near the second edge.
`
`[0047] The dimensions of the tubing and the spacing of the
`perforations and seal lines determine the siZe of the cushions
`Which Will be made from the material. In one embodiment
`Which is suitable for use many shipping cartons, the tubing
`has a ?attened Width of about 8 inches, the roWs of perfo
`rations are spaced about 4 inches apart, and the seal lines are
`about Vs inch Wide, spaced about 3-% inches apart, and
`terminate about 1/2 inch from the second edge of the tubing.
`
`[0048] For storage and shipment, the material can be
`Wound into rolls as in the embodiment of FIG. 1, or it can
`be fan-folded and kept in rectangular boxes. The material
`can either be folded directly into the boxes, or it can placed
`in the boxes after it is folded. The rectangular boxes can be
`stacked more ef?ciently than circular rolls, and fan-folding
`eliminates the need for cores for the material to be Wound
`on. The fan-folded material has additional advantages in that
`the material can be dispensed directly from the boxes, and
`
`does not need to lifted onto a spindle like rolls do. In many
`instances, the boxes can simply be left on the ?oor beneath
`the machine Which processes the material into ?nished
`cushions. Also, With the fan-folded material, there is no need
`for brakes or other means for controlling the inertia of rolls
`as the material is draWn into the machine.
`
`[0049] FIGS. 9-15 illustrate a compact, table-top machine
`88 for ?nishing the cushions from the prefabricated ?lm
`material of FIG. 8. This machine is generally similar to the
`embodiment of FIGS. 4-6, and it has an in?ation tube 89
`Which passes betWeen the ends of seals 79, 81 and the edge
`83 of the material. The tube has three openings 91 in its side
`Wall for injecting air or other gas through the open mouths
`of the chambers. In the embodiment illustrated, air is sup
`plied to the in?ation tube at a pressure on the order of 3 psi
`by a pump 92.
`
`[0050] The in?ation tube is arcuately curved in a horiZon
`tal plane so that the ?lm material Will folloW an arcuate path
`as it passes through the machine. This has been found to be
`advantageous in accommodating the changes in shape Which
`occur in the ?lm as the cushions are in?ated.
`
`[0051] A belt sealer 93 seals the mouths of the chambers
`immediately after the air is introduced into them. As in the
`embodiment of FIGS. 4-6, the sealer has a pair of traveling
`belts 94 positioned on opposite sides of the ?lm material,
`With heater blocks 96 for applying heat to the material
`through the belts. In this embodiment, hoWever, there are no
`feed rollers, and the sealer belts feed the material through the
`machine. The belts are trained about drive rollers 97, take-up
`rollers 98 and guide rollers 101-104.
`
`[0052] The heater blocks are movable betWeen an rest
`position aWay from the belts and a sealing position against
`the belts. They are urged together toWard the sealing position
`by springs 106, and they are moved apart by a cam mecha
`nism (not shoWn).
`[0053] The ?lm material leaving the heat sealer is cooled
`by air from a “muffin” fan 108 through a short duct 109 that
`directs the air doWn onto the ?lm material.
`
`[0054] The knife blade 110 for slitting the edge of the ?lm
`material for separation from the in?ation tube is mounted on
`a holder 111 and positioned at the center of the heaters, With
`the cutting edge of the blade extending into a shalloW slot
`112 in the back side of the tube. Having the blade in this
`location has been found to make it easier for the ?lm
`material to leave the tube, and it also permits the material to
`folloW the arcuate path Which accommodates the changes in
`the shape of the material as the cushions are in?ated.
`
`[0055] Operation of the machine is controlled by a pro
`grammable logic unit (PLU) and a footsWitch (not shoWn).
`In the rest position, the drive motors for the sealer belts and
`the cam mechanism for the heating blocks, the air pump and
`the cooling fan are all turned off. Depressing the footsWitch
`turns on the air pump and the fan, folloWed by the drive
`motors. When the drive motors are actuated, the heating
`blocks press against the belts, and the belts feed the ?lm
`material through the machine. Operation of the motors is
`delayed just enough to alloW the ?rst cushion to ?ll to the
`proper level before it is sealed. Depressing the footsWitch
`again stops the machine, turning off the drive motors, the
`pump and the fan. The temperature of the heaters is also
`controlled by the programmable logic unit.
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 016
`
`

`
`US 2001/0013215 A1
`
`Aug. 16, 2001
`
`[0056] The machine is constructed in modular form on a
`base plate 113 Which is adapted to rest on a table top or
`bench. It has an enclosure comprising an upper cover 114
`and a loWer cover 116, With a holder 117 for a roll of ?lm
`material 73 af?xed to the enclosure. The upper cover has a
`transparent plastic WindoW 118 Which terminates a short
`distance above the upper edge of the loWer cover to provide
`an opening through Which the ?lm material passes. The
`WindoW and the loWer cover serve as a shield to keep the
`material aWay from the sides of the heater blocks. An
`opening 119 is formed in the loWer corner of the WindoW and
`the upper corner of the loWer cover to facilitate insertion of
`the in?ation tube into the ?lm material as the material is
`inserted into the machine. A knife 121 is mounted on the
`upper cover for trimming the corner off the material to
`further facilitate insertion of the tube.
`[0057] The modules Which make up the machine include
`a control module 122, a pump module 123, a take-up module
`124, a heater module 126, and a drive module 127. In FIG.
`11, the machine is illustrated With the covers removed and
`all of the modules in place. In FIG. 12, the control module
`is removed, but the other four modules are still in place. In
`FIG. 13, the control module and the pump module are
`removed, leaving the take-up module, the heater module and
`the drive module. In FIG. 14, the take-up module is also
`removed, and only the heater and drive modules are left. In
`FIG. 15, all but the drive module are removed. With this
`modular construction, repairs and replacements are easily
`made by removing and replacing only the affected module.
`[0058] The embodiment of FIG. 16 is similar to the
`embodiment of FIGS. 9-15 except that it has a guide 129 for
`the prefabricated ?lm material instead of the roll holder. The
`guide is set at a non-perpendicular angle to the front of the
`machine to facilitate travel of the material along an arcuate
`path through the machine. In this embodiment, the ?lm
`material 73 is fan-folded and is fed to the machine from a
`box 131 resting on the ?oor beloW the machine. Although
`the box is illustrated as being generally parallel to the path
`of travel through the machine, that orientation is not critical,
`and the box can be placed at any convenient angle, including
`perpendicular to the machine.
`[0059] The invention has a number of important features
`and advantages. By supplying the material With the perfo
`rations and the major portions of the seals already formed,
`the cushions can be manufactured at the point of use With a
`relatively uncomplicated and inexpensive machine. Since
`the open mouths of the chambers are relatively narroW, the
`cushions can be sealed relatively easily and Without appre
`ciable loss of the gas Which has been injected into them. This
`results in cushions Which are in?ated more uniformly than
`cushions of the prior art.
`[0060] It is apparent from the foregoing that a neW and
`improved system, method and material for making pneu
`matically ?lled packing cushions have been provided. While
`only certain presently preferred embodiments have been
`described in detail, as Will be apparent to those familiar With
`the art, certain changes and modi?cations can be made
`Without departing from the scope of the invention as de?ned
`by the folloWing claims.
`1. In a system for manufacturing pneumatically ?lled
`packing cushions from elongated superposed layers of plas
`tic ?lm material Which are joined together along ?rst and
`second longitudinal edges:
`
`means at a ?rst location for forming longitudinally
`spaced, transversely extending roWs of perforations
`across the material and for sealing the tWo layers
`together along pairs of seal lines betWeen the perfora
`tions, With the seal lines extending transversely from
`the ?rst edge of the material and terminating a short
`distance from the second edge of the material to form
`chambers With open mouths facing the second edge;
`and
`
`means at a second location for injecting gas into the
`chambers through the open mouths and thereafter seal
`ing the tWo layers together along a longitudinally
`extending line Which intersects the pairs of seal lines
`near the second edge to close the chambers and retain
`the gas in the chambers.
`2. The system of claim 1 Wherein the means for injecting
`the gas comprises an elongated tube Which passes betWeen
`the ends of the seals and the second edge of the material,
`With openings in the tube through Which the gas is injected
`into the chambers.
`3. The system of claim 2 Wherein the elongated tube is
`curved so as to impart an arcuate curvature to the ?lm
`material as it passes betWeen the ends of the seals and the
`second edge of the material.
`4. In a method of manufacturing pneumatically ?lled
`packing cushions from elongated superposed layers of plas
`tic ?lm material Which are joined together along ?rst and
`second longitudinal edges, the steps of:
`forming longitudinally spaced, transversely extending
`roWs of perforations across the material at a ?rst
`location;
`sealing the tWo layers together at the ?rst location along
`pairs of seal lines betWeen the perforations, With the
`seal lines extending transversely from the ?rst edge of
`the material and terminating a short distance from the
`second edge of the material to form chambers With
`open mouths facing the second edge;
`
`transporting the material to a second location;
`
`injecting gas into the chambers through the open mouths
`at the second location; and
`
`sealing the tWo layers together at the second location
`along a longitudinally extending line Which intersects
`the pairs of seal lines near the second edge to close the
`chambers and retain the gas in the chambers.
`5. The method of claim 4 Wherein the gas is injected into
`the chambers by passing an elongated tube betWeen the ends
`of the seals and the second edge of the material, and
`injecting the gas through openings in the tube.
`6. In a machine for manufacturing pneumatically ?lled
`packing cushions from a prefabricated plastic ?lm material
`having tWo elongated superposed layers Which are joined
`together along ?rst and second longitudinal edges, roWs of
`perforations extending transversely across the ?lm material,
`and seal lines Which extend from the ?rst edge of the ?lm
`material in a direction generally parallel to the roWs of
`perforations and terminate a short distance from the second
`edge of the ?lm material to form chambers With open
`mouths facing the second edge betWeen the roWs of perfo
`rations: means for feeding the ?lm material along a path; an
`in?ation tube Which passes betWeen the second edge of the
`?lm material and the ends of the seal lines as the ?lm
`
`Free-Flow Packaging Int'l, Inc.
`Exhibit 1005
`Page 017
`
`

`
`US 2001/0013215 A1
`
`Aug. 16, 2001
`
`material travels along the path, With openings in a side Wall
`of the tube through Which gas is injected into the open
`mouths of the chambers; and means for sealing the tWo
`layers together across the mouths of the chambers.
`7. The machine of claim 6 Wherein the means for sealing
`the tWo layers together includes means for sealing along a
`longitudinally extending line spaced inWardly from the
`second edge as the ?lm material travels along the path.
`8. The machine of claim 6 Wherein the means for sealing
`the tWo layers together includes a pair of sealing blocks
`disposed on opposite sides of the path, and a pair of belts
`Which engage the ?lm material and carry it past the sealing
`blocks, With heat being transferred to the ?lm material from
`the sealing blocks through the belts.
`9. The machine of claim 6 including means for slitting the
`?lm material along the second edge after the mouths of the
`chambers are sealed to permit the in?ation tube to eXit from
`the material.
`10. Amaterial for use in the manufacture of pneumatically
`?lled packing cushions, comprising: tWo elongated super
`posed layers of plastic ?lm material Which are joined
`together along ?rst and second longitudinal edges, longitu
`dinally spaced roWs of perforations eXtending transversely
`across the material betWeen edges, and seals bonding the
`tWo layers together along pairs of seal lines Which eXtend
`from the ?rst edge of the material in a direction generally
`parallel to the roWs of pe