US008425994B2
`
`US008425994B2
`
`(12) United States Patent
`Wehrmann
`
`(io) Patent No.:
`
`(45) Date of Patent:
`
`US 8,425,994 B2
`Apr. 23, 2013
`
`(54) WEB AND METHOD FOR MAKING FLUID
`FILLED UNITS
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`(75)
`
`Inventor: Rick Steven Wehrmann, Hudson, OH
`(US)
`
`(73) Assignee: Automated Packaging Systems, Inc.,
`Streetsboro, OH (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 979 days.
`
`3,033,257 A
`3,254,820 A
`3,254,828 A
`3,298,156 A
`3,358,823 A
`3,359,703 A
`3,389,534 A
`3,414,140 A
`3,462,027 A
`3,477,196 A
`
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`
`(Continued)
`
`(21) Appl.No.: 11/594,540
`
`(22) Filed:
`
`Nov. 8, 2006
`
`(65)
`
`Prior Publication Data
`
`US 2007/0054075 A1
`
`Mar. 8, 2007
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`EP
`
`2428246
`1 466 720 A2
`
`9/2002
`10/2004
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`Office action from U.S. Appl. No. 1 1/299,933 dated Dec. 18, 2008.
`
`Related U.S. Application Data
`
`(Continued)
`
`(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 1/02
`B32B 23/00
`
`(52) U.S. CI.
`USPC (cid:9)
`
`(2006.01)
`(2006.01)
`
`428/35.2; 428/34.1; 428/34.2; 428/35.7;
`428/35.9
`
`428/34.1,
`(58) Field of Classification Search
`428/34.2, 35.7, 35.9, 35.2
`See application file for complete search history.
`
`Primary Examiner — Marc 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.
`
`8 Claims, 7 Drawing Sheets
`
`10
`
`•14
`
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`
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`
`•22
`
`> 28
`
`18
`
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`
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`
`28 -<
`
`24
`
`z
`20
`
`T"1'
`
`i
`
`16
`
`Automated Packaging Systems, Inc.
`Exhibit 2003
`Page 001
`IPR2016-00446
`
`

`
`U.S. PATENT DOCUMENTS
`
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`Page 2
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`
`Automated Packaging Systems, Inc.
`Exhibit 2003
`Page 002
`IPR2016-00446
`
`

`
`US 8,425,994 B2
`Page 3
`
`FOREIGN PATENT DOCUMENTS
`
`Advisory action from U.S. Appl. No. 11/194,375, mailed Oct. 9,
`
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`One page drawing, Briggs Bag 1 , illustrates a web ofpre-formed bags
`sold by Applicant for use in Applicant's SP machines more than one
`year prior to the priority date of the present application. Operation of
`Applicant's SP machines is disclosed by U.S. Patent Nos. 4,969,310;
`5,743,070; 5,944,424; 5,722,218; and 6,035,611.
`One page drawing, Goody Bag 1 , illustrates a web ofpre-formed bags
`sold by Applicant for use in Applicant's SP machines more than one
`year prior to the priority date of the present application. Operation of
`Applicant's SP machines is disclosed by U.S. Patent Nos. 4,969,310;
`5,743,070; 5,944,424; 5,722,218; and 6,035,611.
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`38344 dated Dec. 22, 2009.
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`2010.
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`2012.
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`15, 2011.
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`dated Aug. 3, 2012.
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`dated Sep. 24, 2012.
`Office action from U.S. Appl. No. 12/818,318 dated Mar. 8, 2012.
`Automated Packaging Systems, Inc.
`Exhibit 2003
`Page 003
`IPR2016-00446
`
`

`
`US 8,425,994 B2
`Page 4
`
`Response to Examiner's Report for Canadian Appl. No. 2,569,049
`dated Apr. 11, 2012.
`
`Communication from EP Application No. 05755434.7 datedApr. 11,
`
`2012.
`
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`13/036,172 dated Jun. 11,2012.
`
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`
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`
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`
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`
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`Office Action from U.S. Appl. No. 13/036,172 dated Aug. 21, 2012.
`Notice of Allowance from U.S. Appl. No. 1 1/496,654 date Jun. 20,
`2011.
`Office action from U.S. Appl. No. 1 1/818,318 dated Jul. 29, 2011.
`Office action from European Application No. 04252036.1 dated Jul.
`19, 2011.
`Search Report from European Application No. 05755434.7 dated Jul.
`22, 2011.
`
`* cited by examiner
`
`Automated Packaging Systems, Inc.
`Exhibit 2003
`Page 004
`IPR2016-00446
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`US 8,425,994 B2
`
`1
`WEB AND METHOD FOR MAKING FLUID
`FILLED UNITS
`
`RELATED APPLICATIONS
`
`The present application is a divisional application of U.S.
`Ser. No. 11/141,304, filed May 31, 2005 now U.S. Pat. No.
`7,757,459 entitled "Web and Method for Making Fluid Filled
`Units" which claims priority from provisional patent appli-
`cation Ser. No. 60/576,004, entitled "Web for Fluid Filled
`Unit Formation," filed on Jun. 1 , 2004, and provisional patent
`application Ser. No. 60/592,812, entitled "Air Pouch
`Machine," filed on Jul. 30, 2004, all ofwhich are incorporated
`herein by reference in their entirety.
`
`10
`
`15
`
`FIELD OF THE INVENTION
`
`The present application relates to fluid filled units and more
`particularly to plastic webs of interconnected pouches and to
`processes of converting interconnected pouches to fluid filled
`units.
`
`BACKGROUND
`
`Machines for forming and filling dunnage units from 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.
`
`2
`As the spaced apart lines of perforations rupture or otherwise
`separate the adjacent dunnage units are separated.
`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
`is closed at a closing location located along the web path of
`travel . Air is provided into each pouch from a position slightly
`upstream of the closing location to maintain inflation of the
`pouch until it is sealed. For example, the inflation is main
`tained by blowing air into the inflation opening until the a
`trailing transverse seal of the pouch is within 0.250 inches of
`the closing position.
`In one embodiment, inflated dunnage unit arrays comprise
`a single row of interconnected inflated pouches. The pouches
`are defined by first and second layers connected together at an
`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
`20 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-
`35 nection. The hermetic seal and said transverse seals form a
`plurality of inflatable pouches.
`Further advantages and benefits will become apparent to
`those skilled in the art after considering the following descrip-
`t;0n and appended claims in conjunction with the accompa-
`The present invention relates to plastic webs of intercon-
`nected pouches and processes of converting interconnected 40 nying drawings,
`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.
`FIG. 1 illustrates a web for making fluid filled units;
`The gap between each pair ofdunnage units makes separating 45
`FIG. 2 illustrates a web for making fluid filled units;
`adjacent pouches easier and more efficient than with existing
`FIG. 3 illustrates a web with pouches inflated and sealed to
`interconnected arrays of dunnage units.
`form fluid filled units;
`In one embodiment, dunnage units are formed from a pre
`FIG. 4 illustrates a web for making fluid filled units;
`formed flattened tubular web that
`includes a plurality of
`FIG. 5 illustrates a web for making fluid filled units;
`pouches defined by a plurality oftransverse seals. As pouches 50
`FIG. 6 illustrates a web for making fluid filled units;
`are inflated, a gap forming area between adjacent pouches
`FIG. 7A schematically illustrates a plan view of a process
`ruptures or otherwise separates. A gap is formed between
`and machine for converting web pouches to fluid filled units;
`newly formed and adjacent dunnage units. In one embodi
`FIG. 7B schematically illustrates a plan view of a process
`ment, the gap runs between an inflation edge line of perfora
`and machine for converting web pouches to fluid filled units;
`tions and a spaced apart opposite edge line of perforations. 55
`FIG. 8A schematically illustrates an elevational view ofthe
`Pouches are converted to dunnage units by inflating the pouch
`process and machine for converting web pouches to fluid
`with a fluid, substantially maintaining the inflated volume of
`filled units;
`the pouch, and hermetically sealing an inflated pouch.
`FIG. 8B schematically illustrates a an elevational view of
`The gap between the inflation edge line of perforations and
`the process and machine for converting web pouches to fluid
`the spaced apart opposite edge line of perforations makes 60 filled units; and
`separating the dunnage units much simpler and easier than
`FIG. 9 illustrates a process for converting web pouches to
`separating dunnage units that are connected by a continuous
`fluid filled units.
`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.
`
`SUMMARY
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`DETAILED DESCRIPTION
`
`Referring to FIGS. 1 and 2, exemplary illustrations ofwebs
`10 of inflatable pouches 12 are shown. The webs 10 includes
`Automated Packaging Systems,
`Inc.
`Exhibit 2003
`Page 012 IPR2016-00446
`
`

`
`US 8,425,994 B2
`
`4
`3
`a top elongated layer of plastic 14 superposed onto a bottom
`term foreshortening refers to the tendency of the length of a
`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
`5 extend along the entire length of the pouches and remain
`edge 18, 20 is either a fold or a seal that connects the super-
`posed layers 14, 16 along the edges 18, 20. The connection at
`intact during and after inflation. The foreshortening of the
`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. Flowever, the fold and the seal could be reversed or
`can cause undesirable inflation induced stresses. These unde-
`10 sirable stresses caused because sides of adjacent pouches are
`both of the connections could be seals in the FIG. 1 embodi-
`ment. In the example illustrated by FIG. 2, the inflation edge
`connected and restrained, thus, limiting inflation and causing
`18 comprises a frangible connection 21 and the opposite edge
`wrinkles to develop in the layers at the unrestrained inflation
`20 is a hermetic seal. The illustrated frangible connection 21
`opening. The wrinkles can extend into a section of the infla
`is a line of perforations. The size of the perforations is exag
`tion opening to be sealed to complete the dunnage unit, which
`gerated to clarify FIG. 2. The frangible connection 21 maybe 15 may comprise the seal. One reason the seal can be compro-
`formed by folding the inflation edge 18 and pulling the infla
`mised is that wrinkling can cause sections ofthe layers 14, 16
`tion edge over a serration forming wheel (not shown).
`to fold on top of one another. A sealing station of a dunnage
`Referring to FIGS. 1 and 2, a plurality of longitudinally
`machine is typically set to apply the appropriate amount of
`spaced, transverse seals 22 join the top and bottom layers 14,
`heat to seal two layers of material. The sealing of multiple
`16. Generally, each transverse seal 22 extends from the oppo- 20 layers of material in the area of a wrinkle results in a seal that
`site edge 20 to within a short distance ofthe inflation edge 18.
`is weaker than remaining seal areas and may result in a small
`Spaced pairs oflines ofperforations 24, 26 extend through the
`leak or tendency to rupture at loads lower than loads at which
`top and bottom layers terminating a short distance from the
`the dunnage units is designed to rupture.
`edges 18, 20 respectively. A gap forming area 28 extends
`In the embodiment illustrated by FIG. 3, the gap forming
`between each associated pair oflines of perforations 24, 26 . 25 area 28, produces a gap 13 between adjacent pouches upon
`inflation. The gap allows foreshortening of the connected
`The gap forming area 28 opens to form a gap 13 when the
`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
`to a predetermined inflation force. The magnitude of the 30 inflation of each pouch. The gap 13 maintains the inflation
`opening substantially free ofwrinkles as the inflation opening
`inflation force is less than the magnitude of the force needed
`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
`produces an area between the spaced apart lines of perfora- 35 accommodateaprocessforinflatingeachpouchl2intheweb
`to create a row or ladder 11 of dunnage units 12'. The gap
`tions 24, 26 that ruptures or otherwise separates at a force
`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.
`Referring to FIG. 3, the web 10 ofpouches 12 (FIGS. 1 and 40
`In the example illustrated by FIG. 4, the gap forming area
`2) is inflated and sealed to form a row 11 of dunnage units 12'.
`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 45 rations 24, 26 extending inward ofthe web edges 18, 20. Each
`pair of spaced apart lines of perforations 24, 26. The spaced
`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 50 development of a gap 13 between the produced dunnage units
`easier than separating prior art arrays of dunnage units. To
`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 55 or automated process mechanically separates the perforations
`be used to separate dunnage units 12'. A machine can be
`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,
`60 e