US007897220B2
`
`US007897220B2
`
`(12) United States Patent
`Wehrmann
`
`(io) Patent No.:
`
`(45) Date of Patent:
`
`US 7,897,220 B2
`Mar. 1, 2011
`
`(54) WEB AND METHOD FOR MAKING FLUID
`FILLED UNITS
`
`(75)
`
`Inventor: Rick 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 1013 days.
`
`(21) Appl.No.: 11/594,539
`
`(22) Filed:
`
`Nov. 8, 2006
`
`(65)
`
`Prior Publication Data
`
`US 2007/0054074 A1
`
`Mar. 8, 2007
`
`3,389,534 A
`
`6/1968 Pendleton
`
`3,414,140 A
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`
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`
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`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`
`2428246
`
`9/2002
`
`(Continued)
`
`Related U.S. Application Data
`
`OTHER PUBLICATIONS
`
`(62) Division of application No. 1 1/141,304, filed on May
`31, 2005, now Pat. No. 7,757,459.
`
`(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. CI.
`B32B 27/00
`B32B 1/02
`(52) U.S. CI(cid:9)
`
`(2006.01)
`(2006.01)
`. 428/35.2; 428/34.1; 428/34.2;
`428/35.7; 428/35.9; 428/36.9
`
`428/34.1,
`(58) Field of Classification Search
`428/34.2,35.2,35.7,35.9, 36.9
`See application file for complete search history.
`
`(56)
`
`References Cited
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`
`(Continued)
`
`Primary Examiner—Marc A Patterson
`(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
`tion edge of the web comprises a frangible connection that
`allows the inflation edge to be broken by an unsharpened
`object.
`
`12 Claims, 7 Drawing Sheets
`
`-14
`
`¦12
`
`.12
`
`T
`
`-22
`
`> 28
`
`26-
`
`28 -<
`
`24
`
`-22
`
`^20
`
`16
`
`Automated Packaging Systems, Inc.
`Exhibit 2001
`Page 001
`IPR2016-00446
`
`

`
`U.S. PATENT DOCUMENTS
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`
`53/403
`
`53/96
`
`Automated Packaging Systems,
`Inc.
`Exhibit 2001
`Page 002
`IPR2016-00446
`
`

`
`US 7,897,220 B2
`Page 3
`
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`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. Opera
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`4,969,3 10; 5,743,070; 5,944,424; 5,722,218; and 6,035,61 1 .
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`
`* cited by examiner
`
`Automated Packaging Systems, Inc.
`Exhibit 2001
`Page 003
`IPR2016-00446
`
`

`
`U.S. Patent
`
`Mar. 1, 2011
`
`Sheet 1 of 7
`
`US 7,897,220 B2
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`Page 004
`IPR2016-00446
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`

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`U.S. Patent
`
`Mar. 1, 2011
`
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`US 7,897,220 B2
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`Mar. 1, 2011
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`Automated Packaging Systems, Inc.
`Exhibit 2001
`Page 006
`IPR2016-00446
`
`

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`U.S. Patent
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`Mar. 1, 2011
`
`Sheet 4 of 7
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`U.S. Patent
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`Mar. 1, 2011
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`U.S. Patent
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`Mar. 1, 2011
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`U.S. Patent
`
`Mar. 1, 2011
`
`Sheet 7 of 7
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`US 7,897,220 B2
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`1
`WEB AND METHOD FOR MAKING FLUID
`FILLED UNITS
`
`2
`As the spaced apart lines of perforations rupture or otherwise
`separate the adjacent dunnage units are separated.
`
`US 7,897,220 B2
`
`RELATED APPLICATIONS
`
`In one embodiment, an inflated volume is maintained in
`each air pouch by blowing air into an inflation opening of
`5 each pouch until substantially the entire inflation opening of
`the pouch is sealed. In one embodiment, the inflation opening
`The present application is a divisional application of U.S.
`js closed at a closing location located along the web path of
`Ser. No. 1 1/141,304, filed May 31, 2005 now U.S. Pat. No.
`travel . Air is provided into each pouch from a position slightly
`7,757,459 entitled "Web and Method for Making Fluid Ffiled
`upstream of the closing location to maintain inflation of the
`Units", which claims priority from provisional patent appli-
`cation Ser. No. 60/576,004, entitled "Web for Fluid Filled 10 pouch until it is sealed. For example, the inflation is main-
`Unit Formation," filed on Jun. 1 , 2004, and provisional patent
`tained by blowing air into the inflation opening until the a
`application Ser. No. 60/592,812, entitled "Air Pouch
`trailing transverse seal of the pouch is within 0.250 inches of
`Machine," filed on Jul. 30, 2004, all ofwhich are incorporated
`the closing position,
`herein by reference in their entirety.
`
`FIELD OF THE INVENTION
`
`15
`
`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 20
`units.
`
`BACKGROUND
`
`Machines for forming and filling dunnage units from 25
`sheets of plastic are known. Machines which produce dun
`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 30
`units formed from a preformed web are connected by perfo
`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
`
`The present invention relates to plastic webs of intercon
`nected pouches and processes of converting interconnected 40
`pouches to at least one row of dunnage units. In one embodi
`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 ofdunnage units makes separating 45
`adjacent pouches easier and more efficient than with existing
`interconnected arrays of dunnage units.
`In one embodiment, dunnage units are formed from a pre
`formed flattened tubular web that
`includes a plurality of
`pouches defined by a plurality oftransverse seals. As pouches 50
`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 embodi
`ment, the gap runs between an inflation edge line of perfora
`tions and a spaced apart opposite edge line of perforations. 55
`Pouches are converted to dunnage units by inflating the pouch
`with a fluid, substantially maintaining the inflated volume of
`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 60
`separating the dunnage units much simpler and easier than
`separating dunnage units that are connected by a continuous
`line of un-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 65
`and applies forces on one or both of the dunnage units, which
`are connected only by the spaced apart lines of perforations.
`
`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
`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
`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
`of adjacent inflated dunnage units.
`
`In one embodiment, a web for forming dunnage units com
`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
`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
`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
`tion and appended claims in conjunction with the accompa
`nying drawings.
`
`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. 7A 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. 8A schematically illustrates an elevational view ofthe
`process and machine for converting web pouches to fluid
`filled units;
`
`FIG. 8B 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
`Automated Packaging Systems,
`fluid filled units.
`Inc.
`Exhibit 2001
`Page 011
`IPR2016-00446
`
`

`
`US 7,897,220 B2
`
`3
`DETAILED DESCRIPTION
`
`4
`volume of the pouch increases the sides of the pouch have a
`tendency to draw inward. Drawing the sides of the pouches
`inward will shorten the length ofthe sides ofthe pouch unless
`Referring to FIGS. 1 and 2, exemplary illustrations ofwebs
`the sides of the pouch are constrained. In this application, the
`10 of inflatable pouches 12 are shown. The webs 10 includes
`term foreshortening refers to the tendency of the length of a
`a top elongated layer of plastic 14 superposed onto a bottom 5
`layer of plastic 16. The layers are connected together along
`pouch side to shorten as the pouch is inflated. In prior art
`spaced edges, referred to as the inflation edge 18 and the
`webs, the sides of the pouch are restrained, because sides of
`opposite edge 20. In the example illustrated by FIG. 1, each
`adjacent pouches are connected by lines of perforations that
`edge 18, 20 is either a fold or a seal that connects the super
`extend along the entire length of the pouches and remain
`10 intact during and after inflation. The foreshortening of the
`posed layers 14, 16 along the edges 18, 20. The connection at
`the opposite edge 20 is illustrated as a hermetic seal and the
`unrestrained sides, such as the inflation opening, may not be
`connection at the inflation edge 18 is illustrated as a fold in
`uniform. Restraining the sides of adjacent connected pouches
`FIG. 1. Fiowever, the fold and the seal could be reversed or
`can cause undesirable inflation induced stresses. These unde
`both of the connections could be seals in the FIG. 1 embodi-
`sirable stresses caused because sides of adjacent pouches are
`ment. In the example illustrated by FIG. 2, the inflation edge 15 connected and restrained, thus, limiting inflation and causing
`wrinkles to develop in the layers at the unrestrained inflation
`18 comprises a frangible connection 21 and the opposite edge
`opening. The wrinkles can extend into a section of the infla
`20 is a hermetic seal. The illustrated frangible connection 21
`tion opening to be sealed to complete the dunnage unit, which
`is a line of perforations. The size of the perforations is exag
`may comprise the seal. One reason the seal can be compro-
`gerated to clarify FIG. 2. The frangible connection 21 maybe
`formed by folding the inflation edge 18 and pulling the infla- 20 mised is that wrinkling can cause sections ofthe layers 14, 16
`to fold on top of one another. A sealing station of a dunnage
`tion edge over a serration forming wheel (not shown).
`machine is typically set to apply the appropriate amount of
`Referring to FIGS. 1 and 2, a plurality of longitudinally
`heat to seal two layers of material. The sealing of multiple
`spaced, transverse seals 22 join the top and bottom layers 14,
`layers of material in the area of a wrinkle results in a seal that
`16. Generally, each transverse seal 22 extends from the oppo
`site edge 20 to within a short distance ofthe inflation edge 18.
`25 is weaker than remaining seal areas and may result in a small
`leak or tendency to rupture at loads lower than loads at which
`Spaced pairs oflines ofperforations 24, 26 extend through the
`the dunnage units is designed to rupture.
`top and bottom layers terminating a short distance from the
`In the embodiment illustrated by FIG. 3, the gap forming
`edges 18, 20 respectively. A gap forming area 28 extends
`area 28, produces a gap 13 between adjacent pouches upon
`between each associated pair oflines of perforations 24, 26.
`The gap forming area 28 opens to form a gap 13 when the 30 inflation. The gap allows foreshortening of the connected
`pouch sides and thereby reduces the undesirable stresses that
`pouches are inflated (see FIG. 3).
`are introduced during inflation as compared with prior art
`A gap forming area 28 denotes an area, preferably linear in
`webs. In addition, the web with a gap 13 facilitates fuller
`shape, that will rupture or otherwise separate when exposed
`inflation of each pouch. The gap 13 maintains the inflation
`to a predetermined inflation force. The magnitude of the
`inflation force is less than the magnitude of the force needed 35 opening substantially free ofwrinkles as the inflation opening
`is sealed to convert the inflated pouches to a dunnage units.
`to rupture or separate the spaced apart lines of perforations
`The illustrated web 10 is constructed from a heat sealable
`24, 26. The gap forming area 28 can take on a number of
`plastic film, such as polyethylene. The web 10 is designed to
`embodiments, as will be discussed below. Any method that
`accommodate a process for inflating each pouch 12 in the web
`produces an area between the spaced apart lines of perfora
`tions 24, 26 that ruptures or otherwise separates at a force 40 to create a row or ladder 11 of dunnage units 12'. The gap
`forming area 28 creates a gap 13 between dunnage units 12',
`lower than a force needed to rupture or separate spaced lines
`which facilitate a efficient and effective process for separating
`of perforations 24, 26 may be employed to make the gap
`adjacent dunnage units 12' in the row or ladder 11.
`forming area 28.
`In the example illustrated by FIG. 4, the gap forming area
`Referring to FIG. 3, the web 10 ofpouches 12 (FIGS. 1 and
`2) is inflated and sealed to form a row 11 of dunnage units 12'. 45 28 defined by the web 10' includes an easily breakable line of
`The formed dunnage units 12' are configured to be much
`perforations 29 between the spaced lines of perforations 24,
`easier to separate from one another than prior art arrays of
`26. The force needed to rupture or separate the line of perfo
`dunnage units. In the exemplary embodiment of FIG. 3, each
`rations 29 is less than the force needed to separate the perfo
`adjacent pair of dunnage units 12' is connected together by a
`rations 24, 26 extending inward ofthe web edges 18, 20. Each
`pair of spaced apart lines of perforations 24, 26. The spaced 50 pair of perforations 24, 26 and associated more easily break-
`apart lines ofperforations 24, 26 are spaced apart by a gap 13 .
`able line of perforations 29 divide the transverse seal 22 into
`A single row 11 of dunnage units 12' can be graphically
`two transverse sections. As a pouch 12 is inflated, the line of
`described as being in a "ladder" configuration. This configu
`perforation 29 begins to rupture or separate leading to the
`ration makes separating two adjacent dunnage units 12' much
`development of a gap 13 between the produced dunnage units
`easier than separating prior art arrays of dunnage units. To 55 12' (See FIG. 3). Once the pouch 12 is fully inflated, the line
`separate a pair of adjacent dunnage units 12, a worker simply
`of perforations 29 is fully or nearly fully ruptured; however
`inserts an object or objects, such as a hand or hands, into the
`the perforations 24, 26 at the edges remain intact. These
`gap 13 and pulls one dunnage unit 12' away from the other
`perforations 24, 26 are ruptured or separated when a worker
`dunnage unit 12'. In the alternative, a mechanical system can
`or automated process mechanically separates the perforations
`be used to separate dunnage units 12'. A machine can be 60 24, 26.
`configured to insert an obj ect between adjacent dunnage units
`FIG. 5 illustrates another embodiment of the web 10". In
`12' and apply a force to separate the units
`this embodiment the gap forming area 28 comprises an elon
`Referring to FIGS. 1-3, prior to conversion to a dunnage
`gated cut 31 through both layers ofmaterial 14, 16. The cut 31
`unit, a pouch is typically hermetically sealed on three sides,
`extends between each associated pair oflines of perforations
`leaving one side open to allow for inflation. Once the pouch is 65 24, 26. In the embodiment illustrated by FIG. 5, pairs 30 of
`inflated, the inflation opening is hermetically sealed and the
`transverse seals 22' extend from the opposite edge 20 to
`dunnage unit is formed. During the inflation process, as the
`within a short distance of the inflation edge 18. Each of the
`Automated Packaging Systems, Inc.
`Exhibit 2001
`Page 012
`IPR2016-00446
`
`

`
`US 7,897,220 B2
`
`6
`5
`pairs oflines ofperforations 24, 26 and corresponding cuts 31
`and the transverse hermetic seals 22 can be added along with
`are between an associatedpair oftransverse seals 30. It should
`the separated lines of perforations 24, 26 extending inward
`be readily apparent that the seal 22 shown in FIG. 4 could be
`from the inflation and opposite edges 18, 20. The web shown
`used with the cut 3 1 shown in FIG. 5 . It should also be readily
`in FIG. 1 can be produced in the same manner, except the
`apparent that the line ofperforations shown in FIG. 4 could be 5 perforations are not added,
`used with the transverse seals 22' shown in FIG. 5. It shouldbe
`FIGS. 7A, 7B, 8A, 8B and 9 schematically illustrate a
`additionally apparent that any gap forming area 28 can be
`machine 50 and process of converting the webs 10, 10', 10"
`used with either of the transverse seal configurations 22, 22'
`and 10'" to dunnage units 12'. Referring to FIGS. 7A, 7B, 8A
`shown in FIGS. 4 and 5.
`and 8B, a web 10, 10', 10" or 10'" is routed from a supply 52
`(FIGS. 8A and 8B) to and around a pair of elongated, trans-
`FIG. 6 illustrates a further embodiment of the web 10'". In 10
`this embodiment, the gap forming area 28 comprises at least
`versely extending guide rollers 54. The guide rollers 54 keep
`two elongated cuts 32, separated by light connections of
`the web taught as the web 10 is pulled through the machine
`plastic 36, also referred to as "ticks." These connections 36
`50. At location A, the web pouches are uninflated. In the
`hold transverse edges 38, 40 of the pouches 12 together to
`embodiment illustrated by FIG. 5, pouch edges 38,40 defined
`ease handling ofthe web 10, such as handling required during 15 by the cut 31 are close to one another at location A. In the
`installation of the web 10 into a dunnage machine. As the
`embodiments illustrated by FIGS. 4 and 6, the frangible con
`pouches 12 are inflated, the connections 36 rupture or other
`nections 29, 36 are of sufficient strength to remain intact at
`wise break resulting in a gap 13 between the spaced pairs of
`location A.
`perforations 24, 26. This gap 13 allows for full inflation and
`A longitudinally extending guide pin 56 is disposed in the
`reduces the stresses in the layers at the seal site normally 20 web at station B. The guide pin 56 is disposed in a pocket
`ca