SPECIFICATION

BACKGROUND

[0001] The present disclosure is in the technical field of inflatable air cellular material. More particularly, the present disclosure is directed to inflatable air cellular material that have folding zones that encourage the folding zone to deflect upon inflation of the inflatable air cellular material.

[0002] Consumers frequently purchase goods from mail-order or internet retailers, which package and ship the goods to the purchasing consumer via a postal service or other carrier. Millions of such packages are shipped each day. These items are normally packaged in small containers, such as boxes or envelopes. To protect the items during shipment, they are typically packaged with some form of protective dunnage that may be wrapped around the item or stuffed into the container to prevent movement of the item and to protect it from shock.

[0003] Common types of mailing envelope are sometimes referred to as“mailers.” In some cases, these mailers have cushioning to provide some level of protection for the objects transported therein. The outer walls of cushioned mailers are typically formed from protective materials, such as Kraft paper, cardstock, polyethylene- coated paper, other paper-based materials, polyethylene film, or other resilient materials. The inner walls of cushioned mailers are lined with cushioning materials, such as air cellular material (e.g., BUBBLE WRAP™ air cellular material sold by Sealed Air Corporation), foam sheets, or any other cushioning material. The outer walls are typically adhered (e.g., laminated) to the cushioning material when forming the mailers. [0004] When goods are shipped in rigid containers, such as corrugated cardboard boxes, dunnage material is typically added to the containers to take up some of the void space within the containers. Inflated cushions, pillows, or other inflated containers are common void fill materials that are either placed loose in a container with an object or wrapped around an object that is then placed in a container. The cushions protect the packaged item by absorbing impacts that may otherwise be fully transmitted to the packaged item during transit, and also restrict movement of the packaged item within the carton to further reduce the likelihood of damage to the item. Another common form of void fill material is paper, such as Kraft paper, that has been folded or crumped into a low-density, three-dimensional pad or wad that is capable of filling void space without adding significant weight to the container.

[0005] It would be advantageous to automate the packaging process to minimize the amount of time required to package objects properly. However, given the wide variety of ways which objects can be packaged for shipping, automation of the packaging process can be challenging.

SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In a first embodiment, a web material includes two juxtaposed sheets and seals between the two juxtaposed sheets. The two juxtaposed sheets arranged to form an inflatable web that comprises two longitudinal edges and chambers located between the two longitudinal edges. The seals between the two juxtaposed sheets define sides of the chambers. The seals have a pattern so that the chambers formed by the seals include first cells and first interconnecting channels. The web material has a folding zone. In the folding zone, the seals deviate from the pattern so that portions of the chambers in the folding zone include second cells. At least some of the second cells in the folding zone are larger than the first cells outside of the folding zone.

[0008] In a second embodiment, the at least some of the second cells in the folding zone of the first embodiment are larger than the first cells outside of the folding zone in a transverse direction.

[0009] In a third embodiment, the at least some of the second cells in the folding zone of any of the previous embodiments are larger than the first cells outside of the folding zone in a transverse direction and are larger than the first cells outside of the folding zone in a longitudinal direction. [0010] In a fourth embodiment, the portions of the chambers in the folding zone of any of the previous embodiments form the second cells and second interconnecting channels.

[0011] In a fifth embodiment, the seals of the fourth embodiment are arranged so that the second cells and the second interconnecting channels alternate in a longitudinal direction.

[0012] In a sixth embodiment, a width of one of the second cells in one of the chambers of any of the fourth to fifth embodiments is greater than or equal to a width of ones of the first cells in the one of the chambers.

[0013] In a seventh embodiment, a width of one of the second interconnecting channels in one of the chambers of any of the fourth to sixth embodiments is less than or equal to a width of ones of the first interconnecting channels in the one of the chambers.

[0014] In an eighth embodiment, the second cells of any of the previous

embodiments are formed from a conjoining of two adjacent ones of the chambers. [0015] In a ninth embodiment, a gap in one of the seals through the folding zone in the eighth embodiment results in the conjoining of two chambers on either side of one of the seals.

[0016] In a tenth embodiment, every other one of the seals of the ninth embodiment has a gap through the folding zone.

[0017] In an eleventh embodiment, the portions of the chambers in the folding zone of any of the previous embodiments include first large cells and second large cells.

[0018] In a twelfth embodiment, the first large cells of the eleventh embodiment are formed from a conjoining of two adjacent ones of the chambers.

[0019] In a thirteenth embodiment, every third one of the seals of the twelfth embodiment has a gap and wherein a gap in one of the seals through the folding zone results in the conjoining of two chambers on either side of one of the seals.

[0020] In a fourteenth embodiment, the second large cells of any of the eleventh to thirteenth embodiments are formed from straightening of the seals through portions of the folding zone.

[0021] In a fifteenth embodiment, the first large cells and second large cells of any of the eleventh to fourteenth embodiments alternate in a longitudinal direction.

[0022] In a sixteenth embodiment, a method includes obtaining a web material. The web material includes two juxtaposed sheets arranged to form an inflatable web.

The inflatable web comprises two longitudinal edges and chambers located between the two longitudinal edges. The web material includes also includes seals between the two juxtaposed sheets that define sides of the chambers. The seals have a pattern so that the chambers formed by the seals include first cells and first interconnecting channels. The web material has a folding zone. In the folding zone, the seals deviate from the pattern so that portions of the chambers in the folding zone include second cells. At least some of the second cells in the folding zone are larger than the first cells outside of the folding zone. The method further includes folding the web material through the folding zone.

[0023] In a seventeenth embodiment, the method of the sixteenth embodiment further includes inflating the chambers of the web material and sealing closed the chambers after the inflation of the chambers.

[0024] In an eighteenth embodiment, the inflating of the chambers in the seventeenth embodiment occurs after the folding of the web material.

[0025] In a nineteenth embodiment, 19 the inflating of the chambers of any of the seventeenth to eighteenth embodiments causes a deflection of the web material in the folding zone.

[0026] In a twentieth embodiment, the method of any of the seventeenth to nineteenth embodiments further includes forming the inflated web material into a package configured to ship an object.

BRIEF DESCRIPTION OF THE DRAWING [0027] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0028] Figs. 1 A and 1 B depict front and cross-sectional side views, respectively, of a web material in an unfolded state, in accordance with embodiments disclosed herein;

[0029] Figs. 2A, 2B, and 2C depict cross-sectional side, and back views,

respectively, of the web material shown in Figs. 1 A and 1 B in a folded state before inflation of the chambers, in accordance with embodiments disclosed herein; [0030] Fig. 3 depicts an embodiment of the web material shown in Figs. 1A and 1 B after inflation of the web material with a deflection of the web material in the folding zone, in accordance with embodiments disclosed herein;

[0031] Figs. 4A and 4B depict front and cross-sectional side views, respectively, of a web material in an unfolded state, in accordance with embodiments disclosed herein;

[0032] Figs. 5A, 5B, and 5C depict cross-sectional side, and back views,

respectively, of the web material shown in Figs. 4A and 4B in a folded state before inflation of the chambers, in accordance with embodiments disclosed herein;

[0033] Figs. 6A and 6B depict front and cross-sectional side views, respectively, of a web material in an unfolded state, in accordance with embodiments disclosed herein; and

[0034] Figs. 7A, 7B, and 7C depict cross-sectional side, and back views,

respectively, of the web material shown in Figs. 6A and 6B in a folded state before inflation of the chambers, in accordance with embodiments disclosed herein.

DETAILED DESCRIPTION

[0035] As used herein, the term“air cellular material” herein refers to bubble cushioning material, such as BUBBLE WRAP® air cushioning material sold by Sealed Air Corporation, where a first film or laminate is formed (e.g., thermoformed, embossed, calendared, or otherwise processed) to define a plurality of cavities and a second film or laminate is adhered to the first film or laminate in order to close the cavities. Examples of air cellular materials are shown in U.S. Patent. Nos.

3,142,599, 3,208,898, 3,285,793, 3,508,992, 3,586,565, 3,616,155, 3,660,189, 4,181 ,548, 4,184,904, 4,415,398, 4,576,669, 4,579,516, 6,800,162, 6,982,1 13, 7,018,495, 7,165,375, 7,220,476, 7,223,461 , 7,429,304, 7,721 ,781 , and 7,950,433, and U.S. Published Patent Application Nos. 2014/0314978 and 2015/00751 14, the disclosures of which are hereby incorporated by reference in their entirety. [0036] As used herein, an“object” may comprise a single item for packaging or grouping of several distinct items where the grouping is to be in a single package. Further, an object may include an accompanying informational item, such as a packing slip, tracking code, a manifest, an invoice, or printed sheet comprising machine-readable information (e.g., a bar code) for sensing by an object reader (e.g., a bar code scanner). In some embodiments, each of the objects includes an object identifier. In some examples, the object identifier includes one or more of a barcode, a quick response (QR) code, a radio frequency identification (RFID) tag, any other form a machine-readable information, human-readable information, or any combination thereof.

[0037] Inflatable air cellular web materials can be folded for storage in a support and then later inflated to form an inflated folded web. Inflating such folded inflatable web materials presents a number of difficulties. Examples of difficulties inflating folded web materials and examples of overcoming those difficulties are described in U.S. Patent No. 9,969,136, in International Application No. PCT/US2019/013013, in U.S. Patent Application No. 62/845,350, and in U.S. Patent Application No. 62/845,354, the contents of each of which are hereby incorporated by reference in their entirety.

[0038] After inflation, it can be difficult to maintain the inflated web material in a folded configuration. For example, as the inflatable chambers are inflated, the forces on the web material from the gas in the chambers may bias the web material to a lay-flat configuration. This biasing of the web material toward a lay-flat configuration can be overcome by holding longitudinal edges of the film, forming a transverse seal in the film, or in other ways. However, it would also be advantageous for the web material to not be biased completely to a lay-flat configuration.

[0039] The present disclosure describes embodiments of web materials that include two juxtaposed sheets arranged to form an inflatable web and seals between the two juxtaposed sheets. In some embodiments, an inflatable web includes two longitudinal edges and chambers located between the two longitudinal edges. The seals define sides of the chambers. The seals have a pattern so that the chambers formed by the seals include first cells and first interconnecting channels. The web material has a folding zone. In the folding zone, the seals deviate from the pattern so that portions of the chambers in the folding zone include second cells. At least some of the second cells in the folding zone are larger than the first cells outside of the folding zone. The web material can be folded in the folding zone either before and/or after inflation of the chambers. In embodiments disclosed herein, when the chambers of a web material are inflated, the folding zone deflects due to the size differential between the first cells outside of the folding zone and the second cells inside of the folding zone.

[0040] Depicted in Figs. 1A and 1 B are front and cross-sectional side views, respectively, of an embodiment of a web material 100 in an unfolded state. The web material 100 includes a first longitudinal edge 102 and a second longitudinal edge 104. Between the first and second longitudinal edges 102 and 104 are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers 106. In the depicted embodiment, the chambers 106 are in an uninflated state and the chambers 106 are capable of being inflated. In the depicted embodiment, each of the chambers 106 extends substantially transversely across the web material 100 and the pattern of the chambers 106 generally repeats in the longitudinal direction.

[0041] In the depicted embodiment, each of the chambers 106 includes a port 108 that is open and a distal end 1 10 that is closed. The ports 108 are located proximate the first longitudinal edge 102 and the distal ends 1 10 are located proximate the second longitudinal edge 104 so that the ports 108 and the distal ends 1 10 extend substantially transversely across the web material 100. The juxtaposed sheets are sealed between the ports 108 and the distal ends 1 10 such that each of the chambers 106 has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers 106 are capable of being inflated by inserting a gas (e.g., air) through the ports 108. Once the chambers 106 are inflated, the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers 106. In the depicted embodiment, a pair of adjacent chambers 106 are offset so that the cells of one of the chambers 106 are aligned with the interconnecting channels of a subsequent one of the chambers 106.

[0042] The web material includes a first channel 1 12 and a second channel 122.

The first channel 1 12 is located proximate the first longitudinal edge 102 and the second channel 122 is located proximate the second longitudinal edge 104. In the depicted embodiment, each of the first and second channels 1 12 and 122 is a “closed” channel because the two sides of the first channel 1 12 are connected at the first longitudinal edge 102 and the two sides of the second channel 122 are connected at the second longitudinal edge 104. In this way, the first channel 1 12 forms a loop above the ports 108 and the second channel 122 forms a loop below the distal ends 1 10. In other embodiments, one or both of the first and second channels 1 12 and 122 can be an“open” channel where the two sides of the channel do not meet at the longitudinal edge.

[0043] In the depicted embodiment, the first channel 1 12 is in fluid communication with the chambers 106. In some embodiments, a nozzle can be inserted in the first channel 1 12 and direct a gas into the first channel 1 12. The gas inserted into the first channel 1 12 can pass through the ports 108 to inflate the chambers 106. In some embodiments, the nozzle may remain fixed while located within the first channel 1 12 and the web material 100 is moved longitudinally such that the nozzle sequentially inflates the chambers 106. Coupled to the nozzle may be a sealing device configured to close (e.g., seal closed) the ports 108 after inflation of the chambers 106. In the depicted embodiment, the second channel 122 is not in fluid communication with the chambers 106. A longitudinal seal 120 is located in the web material 100 between the distal ends 1 10 and the second channel 122. The longitudinal seal 120 deters any passage of gas between the chambers 106 and the second channel 122.

[0044] In some embodiments, the web material 100 can be folded and formed into a pouch for holding and cushioning an object. In some embodiments, the web material 100 can be folded, inflated, and transversely sealed to form an inflated pouch. An object can be inserted into the pouch and then the pouch can be closed to form a package around the object. In some embodiments, the web material 100 is formed from a material that is suitable for shipping the object. For example, the web material 100 may be opaque.

[0045] When viewing the depiction in Fig. 1 A, the left and right sides of each of the chambers 106 are defined by seals 130. In the depicted embodiment, the seals 130 are nonlinear so that the chambers 106 formed by the seals 130 include cells 132 and interconnecting channels 134. In the depicted embedment, a pair of adjacent chambers 106 are offset so that the cells 132 of one of the chambers 106 are aligned with the interconnecting channels 342 of a subsequent one of the chambers 106. In some embodiments, a pair of adjacent chambers 106 are separated by only one of the seals 130. In some embodiments, each of the seals 130 has a repeating pattern in the transverse direction (the vertical direction when viewing the depiction in Fig. 1A). In the depicted embodiment, the seals 130 have a sinusoidal pattern. Adjacent ones of the seals 130 in the depicted embodiment have patterns that are mirrors of each other. In this way, the cells 132 are substantially circular or ovoidal in shape. In other embodiments, the seals 130 can have other types of patterns so that the cells 132 have a different shape, such as polygonal (e.g., rectangular, hexagonal, octagonal, etc.).

[0046] In the depicted embodiment, the web material 100 includes a folding zone 140. In the folding zone 140, the seals 130 deviate from their pattern outside of the folding zone 140 so that at least some of the cells in the folding zone 140 are larger than the cells 132 outside of the folding zone 140. In the depicted embodiment, the portions of the chambers 106 in the folding zone 140 include large cells 142 and interconnecting channels 144. The seals 130 in the folding zone 140 are configured such that the large cells 142 and the interconnecting channels 144 alternate in the longitudinal direction. The alternating pattern results in any pair of adjacent chambers 106 in the folding zone 140 including one of the large cells 142 and one of the interconnecting channels 144. In the depicted embodiment, the large cells 142 are longer than the cells 132 in the transverse direction (i.e., in the vertical direction when viewing the depiction in Fig. 1 A). In some embodiments, in one of the chambers 106, the width of one of the large cells 142 in the longitudinal direction (i.e. , in the horizontal direction when viewing the depiction in Fig. 1A) is greater than or equal to a width of the cells 132 in the longitudinal direction. Similarly, in some embodiments, in one of the chambers 106, the width of one of the interconnecting channels 144 in the longitudinal direction (i.e., in the horizontal direction when viewing the depiction in Fig. 1 A) is less than or equal to a width of the

interconnecting channels 134 in the longitudinal direction.

[0047] Depicted in Figs. 2A, 2B, and 2C are front, cross-sectional side, and back views, respectively, of the web material 100 in a folded state before inflation of the chambers 106. A longitudinal fold 1 14 has been formed in the web material 100. In the depicted embodiment, the web material 100 is C-folded such that the longitudinal fold 1 14 substantially equidistant from the first and second longitudinal edges 102 and 104. Because the web material 100 is C-folded, the first and second channels 1 12 and 122 are located adjacent to each other. In other embodiments, the web material 100 is J-folded such that the longitudinal fold 1 14 is offset from the middle of the web material 100 between the first and second longitudinal edges 102 and 104.

In the depicted embodiment, the longitudinal fold 1 14 passes through the folding zone 140.

[0048] From the folded state shown in Figs. 2A to 2C, the web material 100 can be stored for later use by an automated packaging station. In some embodiments, the web material 100 can be wound around a cylindrical core initially to form a supply roll of the web material 100. The longitudinal fold 1 14 would be on one side of the supply roll and the first and second channels 1 12 and 122 would be on the other side of the supply roll. When wound into a supply roll, the web material 100 may be suitable for supplying an automated packaging station that can inflate and seal the web material 100 and then form the inflated web material 100 into a pouch for packaging an object. In other embodiments, the web material 100 in the folded state shown in Figs. 2A to 2C can be stored in configurations other than a supply roll for later use by an automated packaging station. [0049] Fig. 3 depicts an embodiment of the web material 100 after inflation of the web material 100 with a deflection of the web material 100 in the folding zone 140. More specifically, due to the size differential of the cells 132 and the large cells 142, the inflation of the chambers 106 has caused the web material 100 to deflect in the folding zone 140. The depicted embodiment, the inflated web material 100 has been placed on a surface 150 with the first and second longitudinal edges 102 and 104 located near the surface 150. The deflection of the web material 100 in the folding zone 140 causes the folding zone 140 tend to rise up and away from the surface 150. This tendency to deflect in the folding zone 140 allows the web material 100 to be folded through the folding zone 140 more easily than in other portions of the inflated web material 100.

[0050] Depicted in Figs. 4A and 4B are front and cross-sectional side views, respectively, of another embodiment of a web material 200 in an unfolded state. The web material 200 includes a first longitudinal edge 202 and a second longitudinal edge 204. Between the first and second longitudinal edges 202 and 204 are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers 206. In the depicted embodiment, the chambers 206 are in an uninflated state and the chambers 206 are capable of being inflated. In the depicted embodiment, each of the chambers 206 extends substantially transversely across the web material 200 and the pattern of the chambers 206 generally repeats in the longitudinal direction.

[0051] In the depicted embodiment, each of the chambers 206 includes a port 208 that is open and a distal end 210 that is closed. The ports 208 are located proximate the first longitudinal edge 202 and the distal ends 210 are located proximate the second longitudinal edge 204 so that the ports 208 and the distal ends 210 extend substantially transversely across the web material 200. The juxtaposed sheets are sealed between the ports 208 and the distal ends 210 such that each of the chambers 206 has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers 206 are capable of being inflated by inserting a gas (e.g., air) through the ports 208. Once the chambers 206 are inflated, the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers 206. In the depicted embodiment, a pair of adjacent chambers 206 are offset so that the cells of one of the chambers 206 are aligned with the interconnecting channels of a subsequent one of the chambers 206.

[0052] The web material includes a first channel 212 and a second channel 222.

The first channel 212 is located proximate the first longitudinal edge 202 and the second channel 222 is located proximate the second longitudinal edge 204. In the depicted embodiment, each of the first and second channels 212 and 222 is a “closed” channel because the two sides of the first channel 212 are connected at the first longitudinal edge 202 and the two sides of the second channel 222 are connected at the second longitudinal edge 204. In this way, the first channel 212 forms a loop above the ports 208 and the second channel 222 forms a loop below the distal ends 210. In other embodiments, one or both of the first and second channels 212 and 222 can be an“open” channel where the two sides of the channel do not meet at the longitudinal edge.

[0053] In the depicted embodiment, the first channel 212 is in fluid communication with the chambers 206. In some embodiments, a nozzle can be inserted in the first channel 212 and direct a gas into the first channel 212. The gas inserted into the first channel 212 can pass through the ports 208 to inflate the chambers 206. In some embodiments, the nozzle may remain fixed while located within the first channel 212 and the web material 200 is moved longitudinally such that the nozzle sequentially inflates the chambers 206. Coupled to the nozzle may be a sealing device configured to close (e.g., seal closed) the ports 208 after inflation of the chambers 206. In the depicted embodiment, the second channel 222 is not in fluid communication with the chambers 206. A longitudinal seal 220 is located in the web material 200 between the distal ends 210 and the second channel 222. The longitudinal seal 220 deters any passage of gas between the chambers 206 and the second channel 222. [0054] In some embodiments, the web material 200 can be folded and formed into a pouch for holding and cushioning an object. In some embodiments, the web material 200 can be folded, inflated, and transversely sealed to form an inflated pouch. An object can be inserted into the pouch and then the pouch can be closed to form a package around the object. In some embodiments, the web material 200 is formed from a material that is suitable for shipping the object. For example, the web material 200 may be opaque.

[0055] When viewing the depiction in Fig. 4A, the left and right sides of each of the chambers 206 are defined by seals 230. In the depicted embodiment, the seals 230 are nonlinear so that the chambers 206 formed by the seals 230 include cells 232 and interconnecting channels 234. In the depicted embedment, a pair of adjacent chambers 206 are offset so that the cells 232 of one of the chambers 206 are aligned with the interconnecting channels 342 of a subsequent one of the chambers 206. In some embodiments, a pair of adjacent chambers 206 are separated by only one of the seals 230. In some embodiments, each of the seals 230 has a repeating pattern in the transverse direction (the vertical direction when viewing the depiction in Fig. 4A). In the depicted embodiment, the seals 230 have a sinusoidal pattern. Adjacent ones of the seals 230 in the depicted embodiment have patterns that are mirrors of each other. In this way, the cells 232 are substantially circular or ovoidal in shape. In other embodiments, the seals 230 can have other types of patterns so that the cells 232 have a different shape, such as polygonal (e.g., rectangular, hexagonal, octagonal, etc.).

[0056] In the depicted embodiment, the web material 200 includes a folding zone 240. In the folding zone 240, the seals 230 deviate from their pattern outside of the folding zone 240 so that at least some of the cells in the folding zone 240 are larger than the cells 232 outside of the folding zone 240. In the depicted embodiment, the portions of the chambers 206 in the folding zone 240 include large cells 242. The large cells 242 are formed from the conjoining of two adjacent ones of the chambers 206. In the folding zone 240, every other one of the seals 230 has a gap through the folding zone 240. The gap in one of the seals 230 results in the conjoining of two chambers on either side of one of the seals 230 at the location of the gap and the formation of a large cell 242 at the conjoining of the two chambers. In the depicted embodiment, the large cells 242 are longer than the cells 232 in the transverse direction (i.e., in the vertical direction when viewing the depiction in Fig. 4A). In the depicted embodiment, the width of the large cells 242 in the longitudinal direction (i.e., in the horizontal direction when viewing the depiction in Fig. 4A) is greater than or equal to a width of the cells 232 in the longitudinal direction.

[0057] Depicted in Figs. 5A, 5B, and 5C are front, cross-sectional side, and back views, respectively, of the web material 200 in a folded state before inflation of the chambers 206. A longitudinal fold 214 has been formed in the web material 200. In the depicted embodiment, the web material 200 is C-folded such that the longitudinal fold 214 substantially equidistant from the first and second longitudinal edges 202 and 204. Because the web material 200 is C-folded, the first and second channels 212 and 222 are located adjacent to each other. In other embodiments, the web material 200 is J-folded such that the longitudinal fold 214 is offset from the middle of the web material 200 between the first and second longitudinal edges 202 and 204.

In the depicted embodiment, the longitudinal fold 214 passes through the folding zone 240.

[0058] From the folded state shown in Figs. 5A to 5C, the web material 200 can be stored for later use by an automated packaging station. In some embodiments, the web material 200 can be wound around a cylindrical core initially to form a supply roll of the web material 200. The longitudinal fold 214 would be on one side of the supply roll and the first and second channels 212 and 222 would be on the other side of the supply roll. When wound into a supply roll, the web material 200 may be suitable for supplying an automated packaging station that can inflate and seal the web material 200 and then form the inflated web material 200 into a pouch for packaging an object. In other embodiments, the web material 200 in the folded state shown in Figs. 5A to 5C can be stored in configurations other than a supply roll for later use by an automated packaging station. [0059] When the web material 200 is inflated, the folding zone 240 of the web material 200 will deflect similar to the deflection of the web material 100 in the folding zone 140, as shown in Fig. 3. More specifically, due to the size differential of the cells 232 and the large cells 242, the inflation of the chambers 206 would cause the web material 200 to deflect in the folding zone 240. The tendency of the web material 200 to deflect in the folding zone 240 allows the web material 200 to be folded through the folding zone 240 more easily than in other portions of the inflated web material 200.

[0060] Depicted in Figs. 6A and 6B are front and cross-sectional side views, respectively, of another embodiment of a web material 300 in an unfolded state. The web material 300 includes a first longitudinal edge 302 and a second longitudinal edge 304. Between the first and second longitudinal edges 302 and 304 are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers 306. In the depicted embodiment, the chambers 306 are in an uninflated state and the chambers 306 are capable of being inflated. In the depicted embodiment, each of the chambers 306 extends substantially transversely across the web material 300 and the pattern of the chambers 306 generally repeats in the longitudinal direction.

[0061] In the depicted embodiment, each of the chambers 306 includes a port 308 that is open and a distal end 310 that is closed. The ports 308 are located proximate the first longitudinal edge 302 and the distal ends 310 are located proximate the second longitudinal edge 304 so that the ports 308 and the distal ends 310 extend substantially transversely across the web material 300. The juxtaposed sheets are sealed between the ports 308 and the distal ends 310 such that each of the chambers 306 has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers 306 are capable of being inflated by inserting a gas (e.g., air) through the ports 308. Once the chambers 306 are inflated, the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers 306. In the depicted embodiment, a pair of adjacent chambers 306 are offset so that the cells of one of the chambers 306 are aligned with the interconnecting channels of a subsequent one of the chambers 306.

[0062] The web material includes a first channel 312 and a second channel 322.

The first channel 312 is located proximate the first longitudinal edge 302 and the second channel 322 is located proximate the second longitudinal edge 304. In the depicted embodiment, each of the first and second channels 312 and 322 is a “closed” channel because the two sides of the first channel 312 are connected at the first longitudinal edge 302 and the two sides of the second channel 322 are connected at the second longitudinal edge 304. In this way, the first channel 312 forms a loop above the ports 308 and the second channel 322 forms a loop below the distal ends 310. In other embodiments, one or both of the first and second channels 312 and 322 can be an“open” channel where the two sides of the channel do not meet at the longitudinal edge.

[0063] In the depicted embodiment, the first channel 312 is in fluid communication with the chambers 306. In some embodiments, a nozzle can be inserted in the first channel 312 and direct a gas into the first channel 312. The gas inserted into the first channel 312 can pass through the ports 308 to inflate the chambers 306. In some embodiments, the nozzle may remain fixed while located within the first channel 312 and the web material 300 is moved longitudinally such that the nozzle sequentially inflates the chambers 306. Coupled to the nozzle may be a sealing device configured to close (e.g., seal closed) the ports 308 after inflation of the chambers 306. In the depicted embodiment, the second channel 322 is not in fluid communication with the chambers 306. A longitudinal seal 320 is located in the web material 300 between the distal ends 310 and the second channel 322. The longitudinal seal 320 deters any passage of gas between the chambers 306 and the second channel 322.

[0064] In some embodiments, the web material 300 can be folded and formed into a pouch for holding and cushioning an object. In some embodiments, the web material 300 can be folded, inflated, and transversely sealed to form an inflated pouch. An object can be inserted into the pouch and then the pouch can be closed to form a package around the object. In some embodiments, the web material 300 is formed from a material that is suitable for shipping the object. For example, the web material 300 may be opaque.

[0065] When viewing the depiction in Fig. 6A, the left and right sides of each of the chambers 306 are defined by seals 330. In the depicted embodiment, the seals 330 are nonlinear so that the chambers 306 formed by the seals 330 include cells 332 and interconnecting channels 334. In the depicted embedment, a pair of adjacent chambers 306 are offset so that the cells 332 of one of the chambers 306 are aligned with the interconnecting channels 342 of a subsequent one of the chambers 306. In some embodiments, a pair of adjacent chambers 306 are separated by only one of the seals 330. In some embodiments, each of the seals 330 has a repeating pattern in the transverse direction (the vertical direction when viewing the depiction in Fig. 6A). In the depicted embodiment, the seals 330 have a sinusoidal pattern. Adjacent ones of the seals 330 in the depicted embodiment have patterns that are mirrors of each other. In this way, the cells 332 are substantially circular or ovoidal in shape. In other embodiments, the seals 330 can have other types of patterns so that the cells 332 have a different shape, such as polygonal (e.g., rectangular, hexagonal, octagonal, etc.).

[0066] In the depicted embodiment, the web material 300 includes a folding zone 340. In the folding zone 340, the seals 330 deviate from their pattern outside of the folding zone 340 so that at least some of the cells in the folding zone 340 are larger than the cells 332 outside of the folding zone 340. In the depicted embodiment, the portions of the chambers 306 in the folding zone 340 include first large cells 342 and second large cells 344. The first large cells 342 are formed from the conjoining of two adjacent ones of the chambers 306. In the folding zone 340, every third one of the seals 330 has a gap through the folding zone 340. The gap in one of the seals 330 results in the conjoining of two chambers on either side of one of the seals 330 at the location of the gap and the formation of a large cell 342 at the conjoining of the two chambers. In the depicted embodiment, the first large cells 342 are longer than the cells 332 in the transverse direction (i.e. , in the vertical direction when viewing the depiction in Fig. 6A). In the depicted embodiment, the width of the first large cells 342 in the longitudinal direction (i.e., in the horizontal direction when viewing the depiction in Fig. 6A) is greater than or equal to a width of the cells 332 in the longitudinal direction. The second large cells 344 are formed from the straightening of the seals 330 through portions of the folding zone 340. In the depicted

embodiment, the second large cells 344 are longer than the cells 332 in the transverse direction (i.e., in the vertical direction when viewing the depiction in Fig. 6A). In the depicted embodiment, the width of the second large cells 344 in the longitudinal direction (i.e., in the horizontal direction when viewing the depiction in Fig. 6A) is substantially the same as a width of the cells 332 in the longitudinal direction. In the depicted embodiment, first large cells 342 and second large cells 344 alternate in the longitudinal direction.

[0067] Depicted in Figs. 7A, 7B, and 7C are front, cross-sectional side, and back views, respectively, of the web material 300 in a folded state before inflation of the chambers 306. A longitudinal fold 314 has been formed in the web material 300. In the depicted embodiment, the web material 300 is C-folded such that the longitudinal fold 314 substantially equidistant from the first and second longitudinal edges 302 and 304. Because the web material 300 is C-folded, the first and second channels 312 and 322 are located adjacent to each other. In other embodiments, the web material 300 is J-folded such that the longitudinal fold 314 is offset from the middle of the web material 300 between the first and second longitudinal edges 302 and 304.

In the depicted embodiment, the longitudinal fold 314 passes through the folding zone 340.

[0068] From the folded state shown in Figs. 7A to 7C, the web material 300 can be stored for later use by an automated packaging station. In some embodiments, the web material 300 can be wound around a cylindrical core initially to form a supply roll of the web material 300. The longitudinal fold 314 would be on one side of the supply roll and the first and second channels 312 and 322 would be on the other side of the supply roll. When wound into a supply roll, the web material 300 may be suitable for supplying an automated packaging station that can inflate and seal the web material 300 and then form the inflated web material 300 into a pouch for packaging an object. In other embodiments, the web material 300 in the folded state shown in Figs. 7 A to 7C can be stored in configurations other than a supply roll for later use by an automated packaging station.

[0069] When the web material 300 is inflated, the folding zone 340 of the web material 300 will deflect similar to the deflection of the web material 100 in the folding zone 140, as shown in Fig. 3. More specifically, due to the size differential of the cells 332 and the large cells 342, the inflation of the chambers 306 would cause the web material 300 to deflect in the folding zone 340. The tendency of the web material 300 to deflect in the folding zone 340 allows the web material 300 to be folded through the folding zone 340 more easily than in other portions of the inflated web material 300.

[0070] For purposes of this disclosure, terminology such as“upper,”“lower,”

“vertical,”“horizontal,”“inwardly,”“outward ly,”“inner,”“outer,”“front,”“rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of“including,”“comprising,” or“having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,”“coupled,” and“mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms“substantially,”“approximately,” and the like are used to mean within 5% of a target value.

[0071] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the

embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and

equivalents fall within the spirit and scope of the present disclosure, as claimed.