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Title:
INFLATABLE CUSHIONING WEB
Document Type and Number:
WIPO Patent Application WO/2018/048745
Kind Code:
A1
Abstract:
An inflatable web (10, 12, 18, 22) includes a top film (30) sealed to a bottom film (32) in selected regions (40) to define (i) a plurality of inflation rows (34) each having a proximal end (42) and a distal end (44) and (ii) an inflation port (60) at the proximal end of each inflation row. Each inflation row (34) includes a plurality of inflatable cells (46) in fluid communication with each other via an interconnecting inflation channel (48) between adjacent inflatable cells of the inflation row. Each plurality of inflatable cells includes a proximal inflatable cell (50), a distal inflatable cell (52), and a plurality of intermediate inflatable cells (54) between the proximal and distal inflatable cells. Each inflatable cell (46) has a peripheral seal boundary (56) defining a peripheral shape (58) of the inflatable cell.

Inventors:
LEPINE JASON (US)
SPERRY LAURENCE (US)
Application Number:
PCT/US2017/049898
Publication Date:
March 15, 2018
Filing Date:
September 01, 2017
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
SEALED AIR CORP (US)
International Classes:
B65D81/03; B31D5/00; B65B31/08; B65B55/20; B65D81/05
Domestic Patent References:
WO2009038859A12009-03-26
Foreign References:
KR20110006202U2011-06-22
US6332823B12001-12-25
FR2056951A11971-05-07
US6800162B22004-10-05
US20060108052A12006-05-25
US7220476B22007-05-22
US7429304B22008-09-30
US7165375B22007-01-23
US8991141B22015-03-31
US6550229B22003-04-22
US6651406B22003-11-25
US8695311B22014-04-15
US20150075114A12015-03-19
US201662288759P2016-01-29
US9591830B22017-03-14
EP1163990A22001-12-19
Attorney, Agent or Firm:
ISAACSON, Jon, M. (US)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1 . An inflatable web having a longitudinal direction and a transverse direction perpendicular to the longitudinal direction, the web comprising:

a top film sealed to a bottom film in selected regions to define:

(i) a plurality of inflation rows, wherein:

each inflation row has a proximal end and a distal end;

each inflation row comprises a plurality of inflatable cells in fluid communication with each other via an interconnecting inflation channel between adjacent inflatable cells of the inflation row, each plurality of inflatable cells comprising a proximal inflatable cell at the proximal end of the inflation row, a distal inflatable cell at the distal end of the inflation row, and a plurality of intermediate inflatable cells between the proximal and distal inflatable cells;

each inflatable cell has a peripheral seal boundary defining a peripheral shape of the inflatable cell;

the peripheral seal boundary of each of the intermediate inflatable cells accommodates two of the interconnecting inflation channels; and

the peripheral shape of the plurality of intermediate inflatable cells of a respective inflation row of the plurality of inflation rows is asymmetrical relative to at least one of (a) a line extending in the transverse direction through the middle of the inflatable cell and (b) a line extending in the longitudinal direction through the middle of the inflatable cell;

the plurality of intermediate inflatable cells of two adjacent inflation rows of the plurality of inflation rows have corresponding peripheral seal boundaries that are spaced apart; and

(ii) an inflation port at the proximal end of each inflation row.

2. The inflatable web of claim 1 wherein the peripheral shape of the plurality of intermediate inflatable cells of the respective inflation row of the plurality of inflation rows is asymmetrical relative to a line extending in the transverse direction through the middle of the inflatable cell.

3. The inflatable web of any one of the previous claims wherein the peripheral shape of the plurality of intermediate inflatable cells of the respective inflation row of the plurality of inflation rows is asymmetrical relative to a line extending in the longitudinal direction through the middle of the inflatable cell.

4. The inflatable web of any one of the previous claims wherein the peripheral shape of the plurality of intermediate inflatable cells of the respective inflation row of the plurality of inflation rows is asymmetrical relative to both of (a) a line extending in the transverse direction through the middle of the inflatable cell and (b) a line extending in the longitudinal direction through the middle of the inflatable cell.

5. The inflatable web of any one of claims 1 to 3 wherein the peripheral shape of the plurality of intermediate inflatable cells of the respective inflation row is heart- shaped. 6. The inflatable web of any one of claims 1 to 4 wherein the peripheral shape of the plurality of intermediate inflatable cells of the respective inflation row is star- shaped.

7. The inflatable web of any one of claims 1 to 4 wherein the peripheral shape of the plurality of intermediate inflatable cells of the respective inflation row is letter- shaped.

8. The inflatable web of any one of claims 1 to 4 and 7 wherein at least two of the plurality of intermediate inflatable cells of the respective inflation row of the plurality of inflation rows have differing peripheral shapes.

9. The inflatable web of claim 8 wherein at least three of the plurality of intermediate inflatable cells of the respective inflation row of the plurality of inflation rows have differing peripheral shapes.

10. The inflatable web of any one of claims 1 to 4 and 7 to 9 wherein at least three of the plurality of intermediate inflatable cells of the respective inflation row of at least three inflation rows of the plurality of inflation rows have differing peripheral shapes within the respective inflation row. 1 1 . The inflatable web of any one of claims 1 to 4 and 7 to 10 wherein the peripheral shape of the plurality of intermediate inflatable cells of at least one of the plurality of inflation rows differs from the peripheral shape of the plurality of intermediate inflatable cells of another of the plurality of inflation rows.

12. The inflatable web of any one of claims 1 to 4 and 7 to 1 1 wherein the peripheral shape of the plurality of intermediate inflatable cells of a first inflation row of the plurality of inflation rows differs from the peripheral shape of the plurality of intermediate inflatable cells of a second inflation row of the plurality of inflation rows that is adjacent the first inflation row.

13. The inflatable web of any one of claims 1 to 4 and 7 to 12 wherein the plurality of intermediate inflatable cells of two adjacent inflation rows of the plurality of inflation rows have corresponding peripheral seal boundaries that correlate with each other.

14. An inflatable web having a longitudinal direction and a transverse direction perpendicular to the longitudinal direction, the web comprising:

a top film sealed to a bottom film in selected regions to define:

(i) a plurality of inflation rows, wherein:

each inflation row has a proximal end and a distal end;

each inflation row comprises a plurality of inflatable cells in fluid communication with each other via an interconnecting inflation channel between adjacent cells of the inflation row, each plurality of inflatable cells comprising a proximal inflatable cell at the proximal end of the inflation row, a distal inflatable cell at the distal end of the inflation row, and a plurality of intermediate inflatable cells between the proximal and distal inflatable cells; each inflatable cell has a peripheral seal boundary defining a peripheral shape of the inflatable cell;

the peripheral seal boundary of each of the intermediate inflatable cells accommodates two of the interconnecting inflation channels; and at least two of the plurality of intermediate inflatable cells of a respective inflation row of the plurality of inflation rows have differing peripheral shapes; and

(ii) an inflation port at the proximal end of each inflation row.

15. The inflatable web of claim 14 wherein at least three of the plurality of intermediate inflatable cells of the respective inflation row have differing peripheral shapes.

16. The inflatable web of any one of claims 14 to 15 wherein at least three of the plurality of intermediate inflatable cells of at least three respective inflation rows of the plurality of inflation rows have differing peripheral shapes within the respective inflation row.

17. The inflatable web of any one of claims 14 to 16 wherein the peripheral shape of the intermediate inflatable cells of at least one of the plurality of inflation rows differs from the peripheral shape of the intermediate inflatable cells of another of the plurality of inflation rows. 18. The inflatable web of any one of claims 14 to 17 wherein the peripheral shape of the intermediate inflatable cells of a first inflation row of the plurality of inflation rows differs from the peripheral shape of the intermediate inflatable cells of a second inflation row of the plurality of inflation rows that is adjacent the first inflation row.

19. The inflatable web of any one of claims 14 to 18 wherein the plurality of intermediate inflatable cells of two adjacent inflation rows of the plurality of inflation rows have corresponding peripheral seal boundaries that are spaced apart.

20. The inflatable web of any one of claims 14 to 19 wherein the peripheral shape of the plurality of intermediate inflatable cells of an inflation row is asymmetrical relative to at least one of (a) a line extending in the transverse direction through the middle of the inflatable cell and (b) a line extending in the longitudinal direction through the middle of the inflatable cell.

21 . The inflatable web of any one of claims 14 to 20 wherein the differing peripheral shapes comprise a letter shape.

22. An inflatable web having a longitudinal direction and a transverse direction perpendicular to the longitudinal direction, the web comprising:

a top film sealed to a bottom film in selected regions to define:

(i) a plurality of inflation rows, wherein:

each inflation row has a proximal end and a distal end;

each inflation row comprises a plurality of inflatable cells in fluid communication with each other via an interconnecting inflation channel between adjacent cells of the inflation row, each plurality of inflatable cells comprising a proximal inflatable cell at the proximal end of the inflation row, a distal inflatable cell at the distal end of the inflation row, and a plurality of intermediate inflatable cells between the proximal and distal inflatable cells;

each inflatable cell has a peripheral seal boundary defining a peripheral shape of the inflatable cell;

the peripheral seal boundary of each of the intermediate inflatable cells accommodates two of the interconnecting inflation channels; and one or more of the plurality of intermediate inflatable cells of a respective inflation row comprise one or more internal sealed regions within the respective peripheral seal boundary of the intermediate inflatable cell; and

(ii) an inflation port at the proximal end of each inflation row.

23. The inflatable web of claim 22 wherein at least three of the plurality of intermediate inflatable cells of the respective inflation row comprise one or more internal sealed regions within the respective peripheral seal boundary of the intermediate inflatable cell.

24. The inflatable web of any one of claims 22 to 23 wherein at least three inflation rows of the plurality of inflation rows comprise one or more of the plurality of intermediate inflatable cells having one or more internal sealed regions within the respective peripheral seal boundary of the inflatable cell.

25. The inflatable web of any one of claims 22 to 24 wherein the peripheral shape of the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is asymmetrical relative to at least one of (a) a line extending in the transverse direction through the middle of the inflatable cell and (b) a line extending in the longitudinal direction through the middle of the inflatable cell.

26. The inflatable web of any one of claims 22 to 25 wherein the peripheral shape of the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is asymmetrical relative to a line extending in the transverse direction through the middle of the inflatable cell.

27. The inflatable web of any one of claims 22 to 26 wherein the peripheral shape of the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is asymmetrical relative to a line extending in the longitudinal direction through the middle of the inflatable cell.

28. The inflatable web of any one of claims 22 to 27 wherein the peripheral shape of the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is asymmetrical relative to both of (a) a line extending in the transverse direction through the middle of the inflatable cell and (b) a line extending in the longitudinal direction through the middle of the inflatable cell.

29. The inflatable web of any one of claims 22 to 27 wherein the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is heart-shaped.

30. The inflatable web of any one of claims 22 to 27 wherein the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is star-shaped.

31 . The inflatable web of any one of claims 22 to 27 wherein the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions is letter-shaped. 32. The inflatable web of any one of claims 22 to 28 and 31 wherein at least two of the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions have differing peripheral shapes.

33. The inflatable web of claim 33 wherein at least three of the one or more of the plurality of intermediate inflatable cells of the respective inflation row comprising one or more internal sealed regions have differing peripheral shapes.

34. The inflatable web of any one of claims 22 to 28 and 31 to 33 wherein at least three of the one or more of the plurality of intermediate inflatable cells comprising one or more internal sealed regions of the respective inflation row of at least three inflation rows of the plurality of inflation rows have differing peripheral shapes within the respective inflation row.

35. The inflatable web of any one of claims 22 to 28 and 31 to 34 wherein the peripheral shape of the one or more of the plurality of intermediate inflatable cells of at least one of the respective inflation rows comprising one or more internal sealed regions differs from the peripheral shape of the plurality of intermediate inflatable cells of another of the plurality of inflation rows comprising one or more internal sealed regions.

36. The inflatable web of any one of claims 22 to 28 and 31 to 35 wherein the peripheral shape of the plurality of intermediate inflatable cells of a first respective inflation row comprising one or more internal sealed regions differs from the peripheral shape of the plurality of intermediate inflatable cells of another of the respective inflation rows comprising one or more internal sealed regions that is adjacent the first inflation row.

37. The inflatable web of any one of claims 22 to 28 and 31 to 36 wherein the one or more of the plurality of intermediate inflatable cells comprising one or more internal sealed regions of two adjacent inflation rows of the plurality of inflation rows have corresponding peripheral seal boundaries that correlate with each other.

Description:
IN THE UNITED STATES PATENT AND TRADEMARK OFFICE

INFLATABLE CUSHIONING WEB Inventors: Jason Lepine (Dedham, MA); Laurence Sperry (Newton, MA)

SPECIFICATION

BACKGROUND

[0001] The presently disclosed subject matter relates to an inflatable web, useful once inflated, for example, as protective packaging cushioning.

SUMMARY

[0002] 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.

[0003] In an embodiment, an inflatable web has a longitudinal direction and a transverse direction perpendicular to the longitudinal direction. The web comprises a top film sealed to a bottom film in selected regions to define (i) a plurality of inflation rows each having a proximal end and a distal end and (ii) an inflation port at the proximal end of each inflation row. Each inflation row comprises a plurality of inflatable cells in fluid communication with each other via an interconnecting inflation channel between adjacent inflatable cells of the inflation row. Each plurality of inflatable cells comprises a proximal inflatable cell at the proximal end of the inflation row, a distal inflatable cell at the distal end of the inflation row, and a plurality of intermediate inflatable cells between the proximal and distal inflatable cells. Each inflatable cell has a peripheral seal boundary defining a peripheral shape of the inflatable cell. The peripheral seal boundary of each of the intermediate inflatable cells accommodates two of the interconnecting inflation channels. The peripheral shape of the plurality of intermediate inflatable cells of a respective inflation row of the plurality of inflation rows is asymmetrical relative to at least one of (a) a line extending in the transverse direction through the middle of the inflatable cell and (b) a line extending in the longitudinal direction through the middle of the inflatable cell. The plurality of intermediate inflatable cells of two adjacent inflation rows of the plurality of inflation rows have corresponding peripheral seal boundaries that are spaced apart.

[0004] In another embodiment, an inflatable web has a longitudinal direction and a transverse direction perpendicular to the longitudinal direction. The web comprises a top film sealed to a bottom film in selected regions to define (i) a plurality of inflation rows each having a proximal end and a distal end and (ii) an inflation port at the proximal end of each inflation row. Each inflation row comprises a plurality of inflatable cells in fluid communication with each other via an interconnecting inflation channel between adjacent inflatable cells of the inflation row. Each plurality of inflatable cells comprises a proximal inflatable cell at the proximal end of the inflation row, a distal inflatable cell at the distal end of the inflation row, and a plurality of intermediate inflatable cells between the proximal and distal inflatable cells. Each inflatable cell has a peripheral seal boundary defining a peripheral shape of the inflatable cell. The peripheral seal boundary of each of the intermediate inflatable cells accommodates two of the interconnecting inflation channels. At least two of the plurality of intermediate inflatable cells of a respective inflation row of the plurality of inflation rows have differing peripheral shapes.

[0005] In another embodiment, an inflatable web has a longitudinal direction and a transverse direction perpendicular to the longitudinal direction. The web comprises a top film sealed to a bottom film in selected regions to define (i) a plurality of inflation rows each having a proximal end and a distal end and (ii) an inflation port at the proximal end of each inflation row. Each inflation row comprises a plurality of inflatable cells in fluid communication with each other via an interconnecting inflation channel between adjacent inflatable cells of the inflation row. Each plurality of inflatable cells comprises a proximal inflatable cell at the proximal end of the inflation row, a distal inflatable cell at the distal end of the inflation row, and a plurality of intermediate inflatable cells between the proximal and distal inflatable cells. Each inflatable cell has a peripheral seal boundary defining a peripheral shape of the inflatable cell. The peripheral seal boundary of each of the intermediate inflatable cells accommodates two of the interconnecting inflation channels. One or more of the plurality of intermediate inflatable cells of a respective inflation row comprise one or more internal sealed regions within the respective peripheral seal boundary of the intermediate inflatable cell.

[0006] These and other objects, advantages, and features of the presently disclosed subject matter will be more readily understood and appreciated by reference to the detailed description and the drawings. BRIEF DESCRIPTION OF THE DRAWING

[0007] 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:

[0008] FIG. 1 is a representative top plan view of an inflatable web;

[0009] FIG. 1 A is a representative top plan view of an alternative inflatable web;

[0010] FIG. 2 is a representative side elevational view of an apparatus for inflating the inflatable web;

[0011] FIG. 3 is a representative partial front elevational view of the apparatus depicted in Figure 2;

[0012] FIG. 4 is a representative perspective view of a portion of the apparatus depicted in Figure 3;

[0013] FIG. 5 is a representative sectional view taken along the line 5-5 shown in Figure 3;

[0014] FIG. 6 is a representative top plan view of the inflated web, inflated from the inflatable web shown in Figure 1 ;

[0015] FIG. 7 is a representative top plan view of an alternative inflatable web; [0016] FIG. 8 is a representative top plan view of the inflated web, inflated from inflatable web shown in Figure 7;

[0017] FIG. 9 is a representative top plan view of an alternative inflatable web; and

[0018] FIG. 10 is a representative top plan view of the inflated web, inflated from inflatable web shown in Figure 9.

[0019] Various aspects of the subject matter disclosed herein are described with reference to the drawings. For purposes of simplicity, like numerals may be used to refer to like, similar, or corresponding elements of the various drawings. The drawings and detailed description are not intended to limit the claimed subject matter to the particular form disclosed. Rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the claimed subject matter.

DETAILED DESCRIPTION

[0020] Inflatable webs (e.g., 10, 12, 18, 22) of the presently disclosed subject matter include a top film 30 sealed to a bottom film 32 in selected regions 40 to define a plurality of inflation rows (e.g., 34, 36, 38). (Figures 1 , 1A, 7, and 9.)

Top and Bottom Films

[0021] Suitable top and bottom films 30, 32 include films having at least one surface conducive to sealing to another film in selected regions. For example, either of top and bottom films 30, 32 may be a monolayer film comprising a heat sealable (e.g. , thermoplastic) polymer, or may be a multilayer film comprising an inside layer comprising a heat sealable polymer. A film inherently has two external surfaces, described herein as an "inside" surface and an "outside" surface opposite the inside surface. The "inside" layer of a multilayer film is the layer forming the inside surface of the film, and the "outside" layer of a multilayer film is the layer forming the outside surface of the film. As used herein, the top and bottom films sealed to each other have their "inside" surfaces (i.e., their inside layers if multilayered) facing each other, with their "outside" surfaces opposing the inside surfaces. [0022] The top and bottom films 30, 32 may be initially distinct, separate films that are superimposed and sealed, or the top and bottom films 30, 32 may be created from a single expanse of film by folding the single expanse of film over onto itself to create a folded edge (e.g., a "C" fold).

[0023] The films 30, 32 may comprise any flexible material that can be manipulated to enclose a gas in the inflatable cells created between the films. Useful materials may include one or more thermoplastic polymers, such as polymers selected from one or more of polyethylene homopolymer, polyethylene copolymer, polypropylene homopolymer, polypropylene copolymer (e.g., propylene/ethylene copolymer), polyester, polystyrene, polyamide, and polycarbonate. Polyethyene homopolymer may be selected from, for example, one or more of low density polyethylene (LDPE) and high density polyethylene (HDPE). Polyethylene copolymer may be selected from, for example, one or more of ionomers, ethylene/vinyl acetate copolymer, ethylene/methyl(meth)acrylate copolymer, heterogeneous (Zeigler-Natta catalyzed) ethylene/alpha-olefin copolymers, and homogeneous (metallocene, single-cite catalyzed) ethylene/alpha-olefin copolymers. Ethylene/alpha-olefin copolymers are copolymers of ethylene with one or more comonomers selected from C3 to C20 alpha-olefins, such as 1 -butene, 1 -pentene, 1 -hexene, 1 -octene, methyl pentene and the like, in which the polymer molecules comprise long chains with relatively few side chain branches, and include, for example, linear low density polyethylene (LLDPE), linear medium density polyethylene (LMDPE), very low density polyethylene

(VLDPE), and ultra-low density polyethylene (ULDPE).

[0024] The top and bottom films 30, 32 may independently be monolayer or multilayer. The top and bottom films may be made by film forming processes known in the art, such as extrusion or coextrusion by melting the component polymer(s) and extruding or coextruding them through one or more flat or annular dies.

Inflatable Web

[0025] Inflatable web 10 has top film 30 sealed to bottom film 32 in selected sealed regions 40 to define a plurality of inflation rows 34 between the films. The inflatable web has a longitudinal (i.e., machine) direction "W" and a transverse direction "T" extending perpendicularly to the longitudinal direction. (Figure 1 .) [0026] Each inflation row 34 has a proximal end 42 and a distal end 44 opposite the proximal end. Each inflation row comprises a plurality of inflatable cells 46. The inflatable cells 46 of an inflation row 34 are in fluid communication with each other via interconnecting inflation channels 48 between adjacent inflatable cells 46. Each plurality of inflatable cells 46 of an inflation row 34 includes a proximal inflatable cell 50 at the proximal end 42 of the inflation row, a distal inflatable cell 52 at the distal end 44 of the inflation row 34, and a plurality of intermediate inflatable cells 54 between the proximal inflatable cell 50 and the distal inflatable cell 52. (Figure 1 .)

[0027] The sealed regions 40 of the top and bottom films 30, 32 define each inflatable cell 46 by a peripheral seal boundary 56 defining the corresponding peripheral shape 58 of the inflatable cell. For example, in Figure 1 the plurality of inflatable cells 46, such as the plurality of intermediate inflatable cells 54, have a peripheral shape of a heart. In Figure 7, the plurality of inflatable cells 104, such as the plurality of intermediate inflatable cells 1 10 between proximal inflatable cell 106 and distal inflatable cell 108, have a peripheral shape of a star. As illustrated, the star is 5-pointed; however, the star shape may be selected from any of, for example, a 4, 5, 6, 7, and 8 sided star. In Figure 9, the plurality of inflatable cells 1 12, such as the plurality of intermediate inflatable cells 1 18 between proximal inflatable cell 1 14 and distal inflatable cell 1 16, have a peripheral shape of a letter, for example, a letter of the English language.

[0028] The plurality of inflatable cells of a respective inflation row may have the same peripheral shape. For example, the plurality of intermediate inflatable cells of a respective inflation row may have the same peripheral shape. (Figures 1 , 1A, and 7.)

[0029] Alternatively, at least any of 2, 3, 5, and/or 8 inflatable cells of the plurality of inflatable cells of a respective inflation row may have differing peripheral shapes. For example, at least any of 2, 3, 5, and/or 8 inflatable cells of the plurality of

intermediate inflatable cells of a respective inflation row may have differing peripheral shapes. (Figure 9.)

[0030] Also by way of example, at least any of 2, 3, 5, and/or 8 of the plurality of inflation cells of the respective inflation row, for example of the plurality of intermediate inflatable cells of the respective inflation row, of at least any of 2, 3, 5, and/or 8 inflation rows of the plurality of inflation rows may have differing peripheral shapes within the respective inflation row. (Figure 9.)

[0031] The peripheral shape of the plurality of inflatable cells of an inflation row, for example the plurality of intermediate inflatable cells of an inflation row, of at least one of the plurality of inflation rows may differ from the peripheral shape of the plurality of inflatable cells of another inflation row, for example the plurality of intermediate inflatable cells of another inflation row, of the plurality of inflation rows. For example, the peripheral shape of the plurality of inflatable cells, for example the plurality of intermediate inflatable cells, of a first inflation row of the plurality of inflation rows may differ from the peripheral shape of the plurality of inflatable cells, for example the plurality of intermediate inflatable cells, of a second inflation row of the plurality of inflation rows that is adjacent the first inflation row.

[0032] In some embodiments, the plurality of intermediate inflatable cells of two adjacent inflation rows have corresponding peripheral seal boundaries that are spaced apart. "Spaced apart" in this sense means that, for the intermediate inflatable cells of a given first inflation row and the intermediate inflatable cells of a given second inflation row adjacent the given first inflation row, there is a spaced region (e.g., spaced region 41 of Figures 1 , 1A, 7, 9) between the peripheral seal boundaries of the adjacent portions of the inflatable cell of the first inflation row and the inflatable cell of the second inflation row, such that the spaced region does not function (i.e., contribute significantly) to the retention of inflation gas (e.g., air) within the inflated inflatable cell by the peripheral seal boundaries. The spaced regions may comprise (a) unsealed areas between the top and bottom films, (b) sealed areas between the top and bottom films, and (c) both (a) and (b).

[0033] The spacing apart of the corresponding seal boundaries of the plurality of intermediate inflatable cells of two adjacent inflation rows may help to distinguish the peripheral shapes to provide greater visual impact for the peripheral shape of the inflatable cells 46.

[0034] In some embodiments the plurality of intermediate inflatable cells of two adjacent inflation rows have corresponding peripheral seal boundaries that correlate with each other. "Correlate" in this sense means that, for the intermediate inflatable cells of a given first inflation row and the intermediate inflatable cells of a given second inflation row adjacent the given first inflation row, the paths of the peripheral seal boundaries of the directly adjacent portions of the inflatable cell of the first inflation row and the inflatable cell of the second inflation row follow each other to coincide.

[0035] Correlating corresponding peripheral seal boundaries of the intermediate inflatable cells of adjacent inflation rows may be spaced apart, as described herein, or alternatively may be shared, wherein there is no spaced region between the corresponding peripheral seal boundaries.

[0036] The selected sealed region 40 may be discontinuous, as shown by inflatable web 12 (Figure 1A), to delineate one or more unsealed areas 102 that are not configured for inflation.

[0037] The peripheral seal boundary 56 of each of the inflatable cells 46

accommodates the interconnecting inflation channels 48; for example, the proximate inflatable cell 50 and the distal inflatable cell 52 are each in fluid communication with a corresponding adjacent intermediate inflatable cell of the plurality of intermediate inflatable cells 54 via a corresponding interconnecting inflation channel 48; and each of the intermediate inflatable cells 54 accommodates two of the interconnecting inflation channels 48, for example to connect two adjacent inflatable cells in fluid communication for inflation, but without significantly interrupting the peripheral seal boundary 56 so that the desired peripheral shape remains largely intact, for example without significantly diminished visual impression or recognition of the peripheral shape.

[0038] The selected seal regions 40 sealing the top and bottom films 30, 32 also define the inflation ports 60 at the proximal end 42 of each of the inflation rows. The inflation port 60 provides a pathway for an inflation gas (e.g., air) to be injected between the top and bottom films 30, 32 into an inflation row (34, 36, 38) to inflate the inflatable cells (46, 104, 1 12, respectively) of the inflation row. (Figures 1 , 7, 9.)

[0039] The inflatable web may comprise top and bottom flanges 62, 64, which are formed by a portion of top film 30 and bottom film 32, respectively, extending beyond the inflation ports 60 and the proximal edge of sealed region 40. For example, flanges 62, 64 of Figure 1 extend beyond inflation ports 60 and sealed region 40 for a given width (shown as width "W"). For example, flanges 62, 64 may each independently be at least ¼ inch or at least ½ inch in width. The flanges may have different widths, or the top and bottom flanges 62, 64 may have equivalent widths as shown in Figure 1 . Flanges 62, 64, in conjunction with inflation ports 60 and the proximal edge of sealed region 40, constitute an open inflation zone of the inflatable web 10 for use in conjunction with an inflation machine to inflate the inflation rows 34. As discussed herein, the inner surfaces of flanges 62, 64 may be brought into close slidable contact with outwardly facing surfaces of an appropriately configured inflation nozzle or other inflation device to provide a partially closed inflation zone which promotes efficient and reliable sequential inflation of the inflation rows 34 without restricting the movement of the web or inflation nozzle that is required to effect a sequential inflation.

[0040] Referring to Figure 1 , the peripheral shape 58 of the inflatable cells 46, for example, the plurality of intermediate inflatable cells 54 of a respective inflation row 34 of the plurality of inflation rows may be asymmetrical relative to at least one of (a) a line 120 extending in the transverse direction through the middle of the inflatable cell and (b) a line 122 extending in the longitudinal direction through the middle of the inflatable cell, and optionally both of (a) and (b). For example, the peripheral shape 58 of a heart for the plurality of inflatable cells 46 of Figure 1 is asymmetrical relative the transverse line 120 and symmetrical relative the longitudinal line 122. Referring to Figure 7, the peripheral shape 124 of a star for the plurality of inflatable cells 104 of Figure 7 is symmetrical relative to the transverse line 120 and

asymmetrical relative the longitudinal line 122. Referring to Figure 9, the peripheral shape 126 of a letter for the plurality of inflatable cells 104 of Figure 9 is

asymmetrical or symmetrical depending on the specific letter shape and its orientation relative to both the transverse line 120 and the longitudinal line 122. For example, the inflatable cell 1 12 having the peripheral shape of letter "N" is asymmetrical relative to both the transverse line 120 and the longitudinal line 122. The inflatable cell 1 12 having the peripheral shape of letter "K" is symmetrical relative to the transverse line 120 and asymmetrical relative the longitudinal line 122. The inflatable cell 1 12 having the peripheral shape of letter Ύ" is asymmetrical relative to the transverse line 120 and symmetrical relative the longitudinal line 122.

[0041] The inflatable cell 104 may comprise one or more internal sealed regions 128 within the peripheral seal boundary 56 of the sealed region 40. (Figures 7.)

Accordingly, one or more of the plurality of inflatable cells 104 of the respective inflation row 36, for example one or more of the plurality of intermediate inflatable cells 1 10 of the respective inflation row 36, may comprise one or more internal sealed regions 128 within the respective peripheral seal boundary 56 of the inflatable cell. (Figure 7.) For example, at least any of 2, 3, 5, and/or 8 of the plurality of inflation cells 104 of a respective inflation row 36, for example of the plurality of intermediate inflatable cells 1 10 of a respective inflation row 36, may comprise one or more internal sealed regions 128 within the peripheral seal boundary 56 of the inflatable cell.

[0042] Also by way of example, at least any of 2, 3, 5, and/or 8 inflation rows of the plurality of inflation rows 36 of the web, may comprise one or more of the plurality of inflatable cells 104 of the respective inflation row 36, for example one or more of the plurality of intermediate inflatable cells 1 10 of the respective inflation row 36, having one or more internal sealed regions 128 within the respective peripheral seal boundary 56 of the inflatable cell.

[0043] Of the inflatable cells having one or more internal sealed regions 128 within the peripheral seal boundary 56, the inflatable cell may further comprises any of two or more and three or more internal sealed regions 128 with the peripheral seal boundary 56. (Figure 7.)

[0044] Figure 9 illustrates inflatable cell 1 12 having a peripheral seal boundary 56in the shape of the letter "A" or the letter "O" having an internal sealed region 128 within the peripheral seal boundary 56 of the sealed region 40.

[0045] The internal sealed regions 128 within the peripheral seal boundary 56 of an inflatable cell may be created as the same time and as part of the formation of the selected sealed regions 40, as described herein. [0046] The configurations of inflatable cells that have internal sealed regions 128 within the peripheral seal boundary 56 of the inflatable cell have particular usefulness in imparting structure that even upon inflation of the inflatable cell provides recognizable features such as those of a facial expression or other pictograph (e.g. , smiley face or other emoji) and certain letters (e.g., "A", "B", "D",

"R"^

[0047] Inflatable web 10 may include one or more lines of weakness 98 that allow sections of predetermined length to be separated from the inflated web. Transverse lines of weakness 98 may comprise, for example, a series of perforations, and extend from the distal edge to the proximal edge, to and through flanges 62, 64 of web 10.

Manufacture of Inflatable Web

[0048] The top and bottom films 30, 32 (i.e., the inside surface of these films) may be sealed together in the selected regions 40 by heat seals or by adhesive seals. For example, top and bottom films 30, 32 may comprise a thermoplastic heat sealable polymer on their inside surface such that, after superposition of films 30, 32, the inflatable web 10 can be formed by passing the superposed top and bottom films between the nip of two cylinders (i.e., rollers), for example, at least one of the rollers ("sealing roller") having a surface of heated raised land areas that correspond in shape to the desired pattern for the selected region 40. The sealing roller applies heat to seal the top and bottom films together to form seals in the selected regions 40, and thereby also creates the inflation rows 34 comprising the inflation ports 60, the inflatable cells 46, and the interconnecting inflation channels 48 in unsealed areas between the top and bottom films. The non-sealing surface areas of the sealing cylinder may be unheated, depressed surface portions - and may be insulated to reduce heat transfer to the films.

[0049] Suitable ways of sealing the top and bottom films 30, 32 together in the selected regions 40 are further disclosed in U.S. Patents 6,800, 162 (attorney file D- 30200) and 7,507,31 1 (attorney file D-30362) and U.S. Pat. App. Publ.

2006/0108052 A1 (attorney file D-30298), each of which is incorporated herein in its entirety by reference. [0050] As discussed herein, the top and bottom films 30, 32 may be initially distinct, separate films that are superimposed and sealed, or the top and bottom films 30, 32 may be created from a single expanse of film by folding the single expanse of film over onto itself to create a folded edge (e.g., a "C" fold) and having the sealing surface of the film creating the inside surfaces of the structure. In such case, the longitudinal distal edge opposite from flanges 62, 64 is closed. (Figure 1 .)

Inflation of the Inflatable Web

[0051] Figures 2 to 5 illustrate a representative apparatus or machine 16 for inflating web 10. Apparatus 16 includes a conveying mechanism, generally indicated at 66, an inflation nozzle 68, and a sealing device 70. Conveying mechanism 66 conveys web 10 along a path of travel as shown, which allows inflation nozzle 68 to sequentially inflate each of the inflation rows 34 (and the inflatable cells therein) and sealing device 70 to seal closed the inflation rows. The "path of travel" (or "travel path") of web 10 refers to the route that such web traverses while being conveyed through apparatus 16 in this manner, as indicated by the shape assumed by the web as it is manipulated by the conveying mechanism.

[0052] Conveying mechanism 66 may include a shaft 72 mounted to housing 73, a pair of adjacent, counter-rotatable cylinders 74 and 76, and a guide roll 81 . Web 10 may be in the form of supply roll 78, which may be wound on spool 80 and mounted on shaft 72. Web 10 is advanced (i.e., unwound) from supply roll 78, with guide roll 81 directing the web between cylinders 74, 76 in a substantially vertical direction as shown. Cylinders 74, 76 are capable of engaging and moving web 10 along its travel path through apparatus 16 when a portion of the film web passes between the cylinders and the cylinders rotate in the directions indicated in Figure 3 against the web. The counter-rotation of the cylinders against web 10 exerts sufficient force on web 10 to cause rotation of supply roll 78, thus dispensing web 10 for travel through apparatus 16 as shown. At least one of cylinders 74, 76 may have an uneven surface (e.g., a knurled or abraded surface as shown in Figure 4, or a grooved or inwardly threaded surface). The opposing cylinder (i.e., opposite the cylinder having an uneven surface) may have a surface formed of a relatively resilient or pliable material, such as silicone or rubber, which may have grooves in the surface thereof. One or both cylinders 74, 76 may be coupled to a motive source (e.g., an electrical, hydraulic, or pneumatic motor) (not shown) having a rotational output to cause the cylinders to rotate.

[0053] Sealing device 70 is preferably positioned immediately downstream from inflation nozzle 78, so that each inflation row 34 may be sealed closed immediately after being inflated and/or contemporaneous with inflation. The sealing device 70 preferably seals closed the corresponding inflation port 60 of inflation row 34 by forming a continuous longitudinal seal 82.

[0054] A representative sealing device is illustrated in Figure 4, where a portion of web 10 has been broken away for clarity, and includes an electrically conductive heating element 84 having a first end secured to a first node 86 and a second end secured to a second node 88. Heating element 84 is positioned between cylinders 74, 76 such that cylinder 74 rotates against the heating element, which is stationary and fixed to platform 90 via nodes 86 and 88. Cylinder 74 preferably includes a circumferential groove in which heating element 84 rides as cylinder 74 rotates against the heating element 84. Cylinder 76 also rotates against the heating element, but at the nip (point of tangential contact) between the cylinders.

[0055] The inflation port 60 of each inflation row 34 is sealed closed when conveying mechanism 66 brings web 10 into moving contact with heating element 84 between cylinders 74, 76 and sufficient current is caused to flow through the heating element 84 to heat it to a sealing temperature sufficient to form longitudinal heat seal 82 between juxtaposed top and bottom films 30, 32 of web 10. The sealing of each inflation port 16 occurs shortly after inflation of the corresponding inflation row 34. In this manner, gas from inflation nozzle 78 is trapped (i.e., enclosed) within each inflatable cell 46, resulting in the formation of an inflated web 14 comprising inflated cells 92. The inflated web 14 may be collected in basket or container 96. (Figure 2.)

[0056] The sealing temperature to form longitudinal seal 82 between top and bottom films 30, 32 of web 10 comprising thermoplastic polymer is that which causes the films 30, 32 to weld or fuse together by becoming temporarily fully or partially molten in the area of contact with the heating element 84. Such temperature (i.e., the sealing temperature) may readily be determined by those of ordinary skill in the art without undue experimentation for a given application based on, for example, the composition and thickness of the films to be sealed, the speed at which the films move against the heating element, and the pressure at which the films and heating element are urged together between cylinders 74, 76. As an example, when films 30, 32 comprise polyethylene-based films ranging in thickness from 0.001 to 0.003 inch (for a combined, juxtaposed thickness ranging from 0.002 to 0.006 inch), the sealing temperature to which heating element 84 is heated may range from 300 to 500° F.

[0057] Heating element 84 may be any device capable of heating to a predetermined temperature sufficient to heat-seal films 30, 32 together. Suitable types of devices for heating element 84 include one or more wires comprising metal and/or other electrically conductive materials; one or more ribbons comprising metal; circuit- printed plastic ribbons (e.g., metal printed on a plastic substrate comprising polyethylene terephthalate); and other suitable electrically conductive devices.

Further, the sealing wire may be fully or partially wrapped about the outer

circumference of a cylinder, as described in one or more of the references

incorporated herein.

[0058] Useful sealing machines and related devices that may be used herein are disclosed, for example, in U.S. Patents 7,220,476 (attorney file D-30259); 7,429,304 (attorney file D-30366); 7, 165,375 (attorney file D-30351 ); 8,991 , 141 (attorney file D-44373-02); 6,550,229 (attorney file D-20084-01 ); 6,651 ,406 (attorney file

D-20083-02); 8,695,31 1 ; U.S. Pat. App. Publ. 2015/00751 14 A1 (attorney file D- 44868); and U.S. Pat. App. Serial No. 62/288,759 (attorney file D-45332), each of which is incorporated herein in its entirety by reference.

[0059] As an alternative to employing a heat sealing device, if one or both of films 30, 32 include bonding material (e.g., an adhesive or cohesive material) located within inflation ports 60. Such a bonding material may forms a seal closing the port when films 30, 32 are pressed together between cylinders 74, 76. Additional disclosure for sealing two films together in this manner is described in U.S. Serial No. 09/591 ,830 (attorney file D-20062) published as counterpart EP 1 163 990 A1 , each of which is incorporated herein in its entirety by reference. [0060] In operation to sequentially inflate the inflation rows 34 (and inflatable cells 46 therein, inflation nozzle 68 of machine 16 is within the travel path of web 10 and is positioned for placement between the top and bottom longitudinal flanges 62, 64 of web 10. (Figures 2 to 5.) Figure 5 illustrates a portion of top film 30 broken away for clarity. As used herein with reference to web 10, the term "longitudinal" refers to the direction of conveyance of web 10 through apparatus 16 as indicated in the drawings; "longitudinal" also corresponds to the direction of the length dimension (longest dimension) of web 10.

[0061] Inflation nozzle 68 comprises a gas outlet port 100 at distal end 102 for injection of gas (e.g., air) into the inflation rows 34. Inflation nozzle 68 is adapted to position gas outlet port 100 closely adjacent to inflation ports 60 and the proximal edge of sealed region 40. While conveying mechanism 66 conveys web 10 along its travel path, inflation nozzle 68 moves continuously and longitudinally between the top and bottom flanges 62, 64 and sequentially inflates the inflation rows 34 and the inflatable cells 46 therein by introducing gas into their corresponding inflation ports 60.

[0062] The positioning of gas outlet port 100 closely adjacent to inflation ports 60 may be achieved by adapting at least a portion of inflation nozzle 68, preferably distal end 102, to move in response to movement of web 10 past the nozzle.

Additionally, distal end 102 of the inflation nozzle is preferably biased towards (i.e. , urged against) inflation ports 60 and the proximal edge of sealed regions 40, and as a result, is caused to move as web 10 moves past inflation nozzle 68. Such movement of the distal end 102 of the inflation nozzle 68 is essentially oscillatory. At the upper end of the oscillation, the inflation nozzle begins to inflate a chamber. At the lower end of the oscillation, the distal end of the nozzle, which has been pulled downwards towards the nip between cylinders 74 and 76 (where the formation of longitudinal seal 82 begins), the distal end disengages with the now-inflated inflation row and rebounds upwards towards the next, adjacent row to be inflated.

[0063] Gas may be introduced by inflation nozzle 68 into the inflation rows 34 at greater than atmospheric pressure ranging, for example, from 1 to 25 psi above atmospheric pressure, such as from 2 to 10 psi. Inflated Web

[0064] The inflated cushioning webs 14, 20, 24 of Figures 6, 8, and 10, respectively, result from the inflation of the inflatable webs 10, 18, and 22 of Figures 1 , 7, and 9, respectively, and have longitudinal seal 82 closing the inflation ports 60 so that the inflation rows 34, 36. and 38 retain the inflation gas to maintain inflated cells 92, 105, 1 13, respectively.

[0065] Any numerical value ranges recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable (e.g., temperature, pressure, time) may range from any of 1 to 90, 20 to 80, or 30 to 70, or be any of at least 1 , 20, or 30 and/or at most 90, 80, or 70, then it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , and 30 to 32, as well as at least 15, at least 22, and at most 32, are expressly enumerated in this specification. For values that are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0066] The above descriptions are those of various embodiments of the invention.

Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents. Except in the claims and the specific examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material, reaction conditions, use conditions, molecular weights, and/or number of carbon atoms, and the like, are to be understood as modified by the word "about" in describing the broadest scope of the invention. Any reference to an item in the disclosure or to an element in the claim in the singular using the articles "a," "an," "the," or "said" is not to be construed as limiting the item or element to the singular unless expressly so stated. The definitions and disclosures set forth in the present Application control over any inconsistent definitions and disclosures that may exist in an incorporated reference. All references to ASTM tests are to the most recent, currently approved, and published version of the ASTM test identified, as of the priority filing date of this application. Each such published ASTM test method is incorporated herein in its entirety by this reference.