CN107107477A - Inflatable packaging with holes - Google Patents

Abstract

A packaged product is disclosed herein. The packaged product includes a flexible cushion including a first film layer and a second film layer sealed to each other by a seal to cooperatively form a wall. The seal defines an inflation chamber between the first film layer and the second film layer that is inflatable with a fluid and configured to contain the fluid. A plurality of holes extend through both membrane layers thereby providing ventilation through the wall. The agricultural product is adjacent to the wall and is cushioned by the inflation chamber and ventilated through the holes.

Description

Inflatable packaging with holes

Cross References to Related Applications

This application claims priority to U.S. Provisional Patent Application No. 62/077,815, entitled "Inflatable Production Package," and U.S. Provisional Patent Application No. 62/103,504, entitled "Inflatable Production Package," the entire contents of which Incorporated herein by reference.

technical field

The present disclosure herein relates to a shipping container, in particular to a flexible shipping container in agriculture.

Background technique

The agricultural industry faces regular challenges related to preserving and transporting products that are prone to spoilage. Typically, products are shipped in film-breathable PE plastic bags, corrugated boxes or pallets, mesh bags, or breathable clamshells. When transporting most products, such as fruit, there may be abuse of the product during transport. Such in-transit damage can hasten fruit ripening or damage the fruit, which in turn can lead to accelerated ripening, browning, and/or bruising of surrounding fruit. This scarring is the result of oxidation of compounds in the fruit. To limit this damage, chemical barriers are sometimes employed. An example of a chemical barrier is citric acid, which is highly reactive towards oxygen and thus reduces oxidation of the product itself. In addition to oxidation, damage to the product exposes nutrients within the cells of the product. This exposure results in colonization with bacteria such as E. coli and Salmonella as well as moulds, fungi and yeasts. To reduce this colonization, the produce is sometimes slightly dehydrated. It is believed that dehydration increases the threshold of product scarring. In some cases, the product is frozen to a temperature of 32 degrees Fahrenheit during storage or shipping in order to slow down the ripening process or extend shelf life.

Frequent causes of product scarring include collisions between tightly packed individual products and between products and shipping containers. Larger and heavier products can also be damaged by the weight of one product resting on another. The viscoelasticity of some products can exacerbate damage. Damage also has a tendency to release certain gases such as ethylene, which increases the rate at which certain products ripen. For example, climacteric shaped fruits continue to ripen after picking and are therefore prone to accelerated ripening by ethylene. Leaves, such as lettuce, are also susceptible to this ripening process. It is believed that ethylene affects the gene that produces the enzyme. Enzymes then catalyze reactions that change the properties of the product. The action of the enzyme leads to the mature reaction. Chlorophyll is broken down and sometimes produces new pigments that change the color of the fruit's skin from green to red, yellow, or blue. The acid is broken down, turning the fruit from sour to neutral. Amylase breaks down starch to produce sugars. This reduces the powdery (powdery) character and increases juiciness. The breakdown of pectin due to pectinase between the fruit cells peels the cells apart so the fruit cells are able to slide past each other. This results in softer fruit. Enzymes also break down large organic molecules into smaller organic molecules that can be volatile (evaporate into the air) and be detected by us as aromas. Producing ethylene also causes more ethylene to be produced. Ripening and damage to fruit during transport is generally considered a negative. For example, with grapes not only are there scars, but once the grapes are broken from the stem or twisted on the stem, the open wound will begin to oxidize and begin to rot as the pulp is exposed to mold spores in the environment. The shelf life can be extended to 60 days by adding protective measures during the transportation of the product. How quickly the product accelerates to ripen is not the most critical, what is most critical is that the buyer is not interested in damaged berries when buying the product making the berries worthless.

To reduce ripening and corruption, various solutions have been proposed. Some of these solutions include partial dehydration, air circulation around the fruit, open storage systems (e.g. open bins), chemical protection (e.g. citric acid), modification of equipment and operating procedures, or pre-treatment of fruit (hydration/ temperature), refrigerated storage, charcoal scrubbing of the product atmosphere to absorb ethylene using carbon dioxide and nitrogen as ripening inhibitors, physical separation from carton (or similar) dividers, and other treatments. These treatments are often costly, cumbersome, or make the quality of the product unsatisfactory. Accordingly, there may be a need in the industry for improved systems and methods.

Contents of the invention

In some embodiments, provided herein is an inflatable packaging element. The inflatable packaging element includes a first film layer and a second film layer sealed to each other by a seal to cooperatively form a flexible structure. The seal defines an inflation chamber between the first film layer and the second film layer that is inflatable with a fluid and configured to contain the fluid. The sealing portion is formed using an adhesive.

In some embodiments, a method of producing an inflatable packaging element is provided. The method includes bonding a first film layer and a second film layer together with a seal to cooperatively form a flexible structure. The seal defines an inflation chamber between the first film layer and the second film layer that is inflatable with a fluid and configured to contain the fluid. The sealing portion is formed using an adhesive.

In some embodiments, an inflatable packaging element is provided. The inflatable packaging element includes a first wall defined by a first film layer and a second film layer sealed to the first film layer by one or more film layer seals. The one or more membrane layer seals define an inflation region between the first membrane layer and the second membrane layer, and the inflation region is inflatable with a fluid and configured to contain the fluid. The inflatable packaging element includes a second wall and one or more wall seals that seal the first and second walls together to form the container. At least one of the one or more membrane seals or the one or more wall seals is formed using an adhesive.

In some embodiments, methods of producing inflatable packaging elements are provided. The method includes sealing a first film layer and a second film layer together with one or more film layer seals to form an inflation chamber between the first film layer and the second film layer and create a first wall. The method includes: inflating the inflation chamber with a fluid such that the fluid is contained within the inflation chamber; and sealing a first wall to a second wall with one or more wall seals to form a container. At least one of the one or more membrane seals or the one or more wall seals is formed using an adhesive.

In some embodiments, a packaged product is disclosed. The packaged product includes a flexible cushion including a first film layer and a second film layer sealed to each other by a seal to cooperatively form a wall. The seal defines an inflation chamber between the first film layer and the second film layer that is inflatable with a fluid and configured to contain the fluid. A plurality of holes extend through both membrane layers, thereby providing ventilation through the wall. The packaged product includes an agricultural product adjacent the wall, cushioned by the inflation chamber, and vented through the aperture.

Description of drawings

Figure 1 shows two sheets of flexible structure according to an embodiment;

Figures 2A-2B show one of the flexible structures of Figure 1 folded;

Figure 2C shows a cross-section of the flexible structure taken along line 2C-2C in Figure 2B;

3A-3B show detailed views of a sealing portion according to an embodiment;

3C-3D illustrate views of a flexible structure with an intermediate sealing portion, according to an embodiment;

Figures 3E to 3F show views of the intermediate seal portion and aperture under tensile and shear stresses;

Figure 4 shows the flexible structure of Figure 1 inflated and packaged to contain a product;

Figures 5A-5B illustrate a flexible structure that is inflated and packaged to contain a product;

Figures 6A-6B illustrate a flexible structure inflated and packaged to contain a product and stored in a crate;

Figure 7 illustrates an exemplary inflatable package sealing device for sealing a flexible structure;

Figure 8 illustrates a section of a flexible structure showing a section through a transverse seal and an inflation chamber, according to various embodiments;

Figure 9 illustrates a membrane that is embossed or otherwise formed to create a structural/thermal shape, according to various embodiments;

10A-10B illustrate packaging structures according to various embodiments; and

Figure 11 shows a packaging structure according to various embodiments.

detailed description

The present disclosure relates to a protective packaging, protective system and method for converting uninflated material into an inflated cushion that can be used as Buffering or protection for packaging and transporting goods (specifically produce or other agricultural products). Illustrative embodiments will now be described to provide a thorough understanding of the present disclosure. Those of ordinary skill in the art will appreciate that the disclosed embodiments can be adapted and modified to provide alternative embodiments for other applications and that other additions can be made to the present disclosure without departing from the scope of the present disclosure. and modify. For example, features of illustrative embodiments may be combined, separated, interchanged, and/or rearranged to create other embodiments. Such modifications and variations are intended to be included within the scope of this disclosure. Similarly, the subject matter discussed herein can also be incorporated into the various systems disclosed in the cited references. Embodiments are not meant to be standalone, but may be combined with other embodiments from other referenced applications or with various other embodiments disclosed herein.

FIG. 1 is a schematic illustration of a flexible structure 100 according to various embodiments. Flexible structures can be formed in any of a number of ways. For example, a plurality of interconnected flexible structures (eg, 100a, 100b) may form a continuous sheet.

Successive sheets may be separated by perforations or other areas of weakness to help separate the individual protective packaging units 100a, 100b from each other. The line of weakness 149 may extend transversely to separate units arranged longitudinally in series with respect to each other. When separated, the broken lines of weakness define the longitudinal ends of the units 100a, 100b. These lines of weakness may be formed as perforations or similar structures that allow a user to easily separate the units by tearing them open with his or her hands. As used herein, a perforation may be a small tick in the material that causes the tear to be directed to the next tear in the material. The little part that makes the ticking sound. This tick-tick-tear-tear-to-the-next-tear can then spread along the length of the perforation, allowing easy separation. Lines of weakness, and specifically perforations, can be distinguished from holes described herein because lines of weakness refer to structures that allow a continuous extension of a separable feature, whereas holes are not such structures unless specifically indicated.

FIG. 1 illustrates an embodiment of separate flexible structures (eg, 100a or 100b ), each capable of forming a container 50 , as shown in FIG. 2B . Figure 2A shows an example of forming flexible structures 100a, 100b into a container 50 according to an embodiment. The container is operable to enclose, hold, separate and/or protect the contents stored in the container. Alternatively, flexible structure 100 may be used in a flat form as shown in FIG. 1 . In this form, the flexible structure 100 can be used as a separator. Dividers may be positioned between layers of cargo and thereby separate different quantities of cargo. For example, a divider may be located in a box with a layer of product on top of the divider. Another divider can be placed on top of the first layer of products, and yet another (more) product is placed on top of another divider, and so on. In this way, one layer of product is separated from another, thereby protecting the layers from each other and from external conditions. Each of the various features discussed herein may apply whether the flexible layer is formed into the container 50, used in its flat form, or used in another form.

According to various embodiments, the flexible structure 100 may include a plurality of membrane layers 105 , 107 . The first film layer 105 has a first longitudinal edge 102 and a second longitudinal edge 104 , while the second film layer 107 has a first longitudinal edge 106 and a second longitudinal edge 108 . The second film layer 107 may be aligned with the first film layer 105 so as to overlap and be generally coextensive, ie at least the respective first longitudinal edges 102, 106 are aligned with each other and/or at least the respective second longitudinal edges 104, 108 are mutually aligned. alignment. In some embodiments, the membrane layers 105, 107 partially overlap the inflatable region in the overlapping region. The film layers 105 , 107 may be joined to define a first longitudinal edge 110 and a second longitudinal edge 112 of the film 100 . The first film layer 105 and the second film layer 107 can be formed from a single sheet of web material, a flat tube of web material with one edge slit, or two sheets of web material. For example, the first film layer 105 and the second film layer 107 can comprise a single sheet of web material that is folded to define joined second edges 104, 108 (e.g., a "c-fold film (c -fold)"). As another example, the first film layer 105 and the second film layer 107 can comprise tubes of web material (e.g., flat tubes) having along the aligned first longitudinal edges 102, 106 slit. In an embodiment, the first film layer 105 and the second film layer 107 comprise two separate sheets of web material that are joined, sealed, or otherwise joined along aligned second edges 104, 108. way attached together.

According to various embodiments, structure 100 may be flexible. For example, structure 100 may be sufficiently flexible that it bends easily under its own weight. The structure 100 can be flexible enough that a user can bend it into different shapes without permanently distorting, cracking or destroying the structure 100 . Thermoformed plastic packaging is not a flexible material, but rather a semi-rigid material that does not absorb the shock of impact and vibration.

The disclosed film layers 105, 107 may comprise single-layer films or multi-layer films. One or more layers may comprise a polymer. Where the film layers 105, 107 comprise multilayer films, the multiple layers can comprise polymers of different composition. In some embodiments, the disclosed layers may be selected from ethylene, amides, or ethylene polymers, copolymers, and combinations thereof. The disclosed polymers can be polar or non-polar. The disclosed ethylene polymers may be substantially non-polar forms of polyethylene. In many cases, ethylene polymers can be polyolefins made by the copolymerization of ethylene and another olefin monomer, such as an alpha-olefin. The ethylene polymer may be selected from low density polyethylene, medium density polyethylene or high density polyethylene, or a combination of the above polyethylenes. In some cases, the densities of the various polyethylenes vary, but in many cases low density polyethylenes can range, for example, from about 0.905 g/ ^cm3 or less to about 0.930 g/ ^cm3 , medium density polyethylenes Ethylene may have a density, for example, from about 0.930 g/cm ³ to about 0.940 g/cm ³ , and high density polyethylene may have a density, for example, from about 0.940 g/cm ³ to about 0.965 g/cm ³ or greater. The ethylene polymer may be selected from linear low density polyethylene (LLDPE), metallocene linear low density polyethylene (mLLDPE), high density polyethylene (HDPE), medium density polyethylene (MDPE) and low density polyethylene (LDPE ).

In some embodiments, the polar polymer can be a non-polar polyethylene, which can be modified to impart polar characteristics. In other embodiments, the polar polymer is an ionomer (eg, a copolymer of ethylene and methacrylic acid, E/MAA), a high vinyl acetate content EVA copolymer, or other polymers with polar properties. In some embodiments, the modified polyethylene may be an anhydride-modified polyethylene. In some embodiments, maleic anhydride is grafted to the olefin polymer or copolymer. Modified polyethylene polymers can react rapidly when coextruded with polyamides and other polymers containing ethylene (eg, EVOH). In some cases, a layer or sublayer comprising modified polyethylene may form covalent bonds, hydrogen bonds, and/or dipole-dipole bonds with other layers or sublayers, such as the sublayer or layer comprising a barrier layer. pole interaction. In many embodiments, the modification of the polyethylene polymer can increase the number of atoms on the polyethylene available for bonding. For example, maleic anhydride is used to modify polyethylene to add acetyl groups to polyethylene, and the modified polyethylene can then bond with polar groups of the barrier layer (eg, hydrogen atoms on the nylon backbone). The modified polyethylene can also form bonds with other groups on the nylon backbone as well as polar groups of other barrier layers (for example, alcohol groups on EVOH). In some embodiments, the modified polyethylene can form chain entanglements and/or van der Waals interactions with unmodified polyethylene.

Mixtures of ethylene and other molecules can also be used. For example, ethylene vinyl alcohol (EVOH) is a copolymer of ethylene and vinyl alcohol. EVOH has polar properties and can assist in creating a gas barrier. EVOH can be produced by the polymerization of ethylene and vinyl acetate to give ethylene vinyl acetate (EVA) copolymers after hydrolysis. EVOH can be obtained by saponification of ethylene-vinyl acetate copolymer. The ethylene-vinyl acetate copolymer can be produced by a known polymerization method (for example, solution polymerization, suspension polymerization, emulsion polymerization, etc.), and saponification of the ethylene-vinyl acetate copolymer can also be performed by a known method. Generally, EVA resins are prepared via high-pressure autoclaves and tubular processes.

Polyamides are high molecular weight polymers having amide bonds along the molecular chain structure. Polyamides are polar polymers. Nylon polyamide, which is a synthetic polyamide, has good physical properties of high strength, high stiffness, abrasion resistance and chemical resistance, and low gas permeability (for example, oxygen).

Other materials and configurations can be used. The disclosed flexible structure 100 can be wrapped around a hollow tube, a solid core, or folded into a fan-folded box, or into another desired form for storage and transportation.

According to various embodiments, the layers, walls, structures, etc. discussed herein may be sealed together by any process such as adhesive bonding, friction, welding, fusing, heat sealing, laser sealing to form the described structures. and ultrasonic welding. For example, the layers 105, 107 may be sealed together according to any known method to form the inner inflation chamber. Furthermore, the flexible structure 100 which has been formed from the layers 105, 107 may eg be sealed to itself or to another flexible structure 100 in order to form other structures (container 50). For example, layers or structures may be heat sealed together, or adhesively sealed together. Adhesives that are operable to adequately seal the inflation chamber to contain gas under shipping pressure may be suitable. These stresses may result from stacking the flexible structure 100 under multiple layers of shipping products. In some embodiments, the adhesive can be cured by exposing the adhesive to electromagnetic radiation. Adhesives may be sensitive to electromagnetic radiation in certain regions of the electromagnetic radiation spectrum. For example, the adhesive can be an ultraviolet (UV) curable adhesive. For example, a heat seal adhesive may be applied to one or both of the film layers 105, 107, which may then be laid on top of each other and subsequently sealed together by applying a UV light seal. Such adhesives and methods, and similar adhesives and methods, are described in more detail in US Patent No. 8,404,071, the entire contents of which are hereby incorporated herein by reference. The adhesive may also be a pressure sensitive adhesive or any other adhesive. As discussed herein, either seal may be formed by heat sealing only, adhesive sealing only, both types of heat and adhesive sealing, or any other type of sealing. The adhesive may be a UV curable laminating adhesive, which may be used with some embodiments of wet lamination. For example, the adhesive may be a UV curable flexographic low odor laminating adhesive for film-to-film UV wet lamination applications. The Brookfield viscosity of the adhesive may be between about 700 cps to about 1000 cps at 77 degrees Fahrenheit. The density of the adhesive can be equal to or about equal to 8.6 lbs/gallon. The adhesive can have a low odor and/or clear liquid appearance. The solid content of the binder is 100%. The curing speed of the adhesive can be between 150 FT/MIN to 220 FT/MIN at 1 x 300 watts/lamp. Adhesive coverage may be equal to or approximately equal to 5300 FT/GAL at a thickness of 0.3 mil. The curing absorbed irradiance of the adhesive may be equal to or about equal to 1.3 ^Wcm2 . These adhesives cure at a rapid rate to provide durable high quality bonds to specific films such as treated LLDPE, LDPE and metallocene catalyzed LLDPE and polypropylene. These adhesives have strong adhesion to both films and some papers. These binders are also cationic based and do not do instant cure well in inks containing water or solvent amines. In some embodiments, the coating thickness of the adhesive may be from about 0.2 mil to about 0.5 mil. A typical anilox roll in the range of 150Q to 200Q will provide a suitable coat weight. Best results can be achieved on smooth films and some papers. Excellent results have been obtained with polyethylene and polypropylene films. The membrane surface can be treated to 40-45 dynes/cm to improve adhesion to low surface energy membranes.

According to various embodiments, the layers 105 , 107 may be sealed together using a seal 118 . Seal 118 may be continuous enough to retain gas injected into flexible structure 100 . In this manner, each of the flexible structures (eg, 100a, 100b) may be inflated to form a cushion or inflation pad. The cushion or inflation pad may be in the form of a structural container 50 (see eg FIGS. 2A-2B ) or in the form of a flat sheet as shown in FIG. 1 . Any number of forms may be used to separate the first quantity of products from the second quantity of products. For example, as a flat sheet, the inflated flexible structure may be arranged between layers of the product. As a structural container 50, the product can be protected by arranging it in an inflated structure.

As shown in FIG. 1 , the web 100 can include a series of transverse seals 118 arranged along the longitudinal extension of the web 100 . Each transverse seal 118 extends from the longitudinal seal 112 towards a longitudinal inflation region which may be, for example, an inflation channel 114 which, in addition to directing gas between the membrane layers 105, 107 It has a substantially or entirely closed perimeter around its longitudinal axis except at a location to receive a longitudinal inflation nozzle therein. Transverse seal 118 may be straight as shown, or may be curved, zigzag, or formed into any geometry or shape suitable for the application. Alternatively, the inflation area can be provided by open lateral edges, such as flaps, which are held over transverse nozzles to blow gas between the membrane layers. In the illustrated embodiment, the inflation channel 114 is closed by the first longitudinal seal 110 at the side opposite the inflation chamber 120 . Each transverse seal 118 has a first end 122 adjacent to the second longitudinal seal 112 and a second end 124 that is sealed to the first longitudinal seal of the film 100 . Portions 110 are spaced apart by a transverse dimension d. The inflation chamber 120 is defined within boundaries formed by various seals operable to trap gas therein. For example, inflation chamber 120 may be defined by longitudinal seal 112 , or longitudinal seal 140 and a pair of adjacent transverse seals 118 . The inflation chamber may be closed by a longitudinal seal 140 . Flexible structure 100 may be inflated in a flat form, or it may have been formed into a container structure (eg, container 50 ) after inflation. In one example, the flexible structure is formed by sealing the layers 105, 107 together. The flexible structure is then inflated, and the flexible structure forms the container 50 after inflation. In another example, the flexible structure is formed by sealing the layers 105, 107 together. The flexible structure is then formed into a container 50 and sealed in container form. After forming into container 50, the flexible structure is inflated and the inflated location is sealed.

Each transverse seal 118 shown in FIG. 1 may extend substantially perpendicular to the second longitudinal seal 112 . However, it will be appreciated that other arrangements of the transverse seal 118 are possible. For example, in some embodiments, transverse seal 118 has a corrugated or Z-shaped pattern. Transverse seal 118 may be continuous and/or discontinuous. The transverse seal 118 and sealed longitudinal edges 110, 112 can be formed by any of a variety of techniques known to those of ordinary skill in the art, such as those sealing techniques described above.

It is possible to provide an inflation region, eg a closed passage, which may be the longitudinal inflation channel 114 . A longitudinal inflation channel 114 as shown in FIG. 1 is disposed between the second end 124 of the transverse seal 118 and the first longitudinal edge 110 of the membrane. The longitudinal inflation channel 114 may extend longitudinally along the longitudinal sides 110 and an inflation opening 116 is disposed on at least one end of the longitudinal inflation channel 114 . The longitudinal inflation channel 114 has a transverse width D. In the embodiment of FIG. 1 , the distance of the transverse width D is substantially equal to the distance of the transverse dimension d between the longitudinal edge 110 and the second end 124 . However, it is understood that in other configurations, other suitable dimensions for the lateral width D can be used. According to other embodiments, the longitudinal inflation channel may extend to the center of the flexible structure 100, wherein inflation openings extend from either side of the longitudinal inflation channel into the inflation chamber. In this example, the longitudinal inflation channel may form a boundary between the two walls of the container 50 . Alternatively, the central longitudinal inflation channel may be formed in a single wall, wherein each individual wall of the container 50 has its own individual longitudinal inflation channel. In various embodiments, each individual flexible structure (eg, 100a) can be inflated without inflating the other structures (eg, 100b). Also, this is independent of whether the structure is formed as a container or not. The structure may be inflated with a nozzle as described below, or the structure may include a one-way valve to allow inflation. In various embodiments, flexible structures (eg, 100a and 100b ) can be continuously inflated. This can be done with an entire roll, stack or other number of such structures, regardless of whether the structures form a container or not.

The second longitudinal edge 112 and the transverse seal 118 cooperate to define the boundary of the inflatable chamber 120 . In various embodiments, the inflatable chamber 120 may also include an intermediate seal 128 . The intermediate seal 128 may seal the layers 105 , 107 to each other in an intermediate region in the inflatable chamber 120 . As shown in FIG. 1A , intermediate seal 128 may be aligned laterally across inflatable chamber 120 , or may be aligned longitudinally across inflatable chamber 120 . The intermediate seal may allow gas to pass through the seal such that the intermediate seal does not block the inflatable chamber, thereby allowing the entire inflatable chamber to be inflated. The intermediate seal can serve various functions. In various embodiments, the intermediate seal 128 may create bendable lines that allow the web 100 to be softer, the softer web 100 being able to bend or fold easily. This flexibility allows the film 100 to be wound on regularly shaped objects as well as irregularly shaped objects. In various embodiments, the intermediate seal 128 may provide multiple openings from the inflation channel 114 into the inflatable chamber 120 . See, for example, the intermediate seal 128 directed laterally between the transverse seals along the left side of FIG. 1 adjacent the inflation channel 114 . In various embodiments, the intermediate seal 128 may provide a fold line to fold the layers 105, 107 over top of each other. See, for example, the intermediate seal 128 oriented longitudinally along the center of the film 100 in FIG. 1 between the transverse seals.

According to various embodiments, the transverse seal 118 may include an intermediate seal portion 129 . The intermediate sealing part 129 may have a larger area relative to the area of the sealing part 118 . The intermediate seal portion 129 may be an alternate seal configuration along the length of the transverse seal 118 , the intermediate seal portion 129 being operable to provide additional functionality beyond that of the transverse seal 118 . For example, the intermediate sealing portion 129 may seal a sufficient area of the layers 105 , 107 to position the holes therein without piercing the inflation chamber 120 . Additionally or alternatively, the intermediate seal portion 129 may provide a bendable line for additional flexibility, or a bendable location for modifying the shape of the membrane 100 .

The intermediate seal portion 129 may be the seal where the layers 105, 107 are attached to each other. The intermediate seal portion 129 may be a narrow seal where (eg, a continuation of the seal 118 ) defines the section of the intermediate seal portion 129 . Intermediate seal portion 129 may be the region where a wider solid seal is formed along seal 118 (i.e., the region where layers 105, 107 are attached may be in the center of intermediate seal portion 129 where layers 105, 105, 107 are not present. continuous solid seal of the unattached area of 107). This solid seal may form a more rigid portion of the web 100 . The intermediate seal portion 129 may be the area where a seal (eg, partial seal 118 ) encloses portions of the layers 105 , 107 that are not attached. This non-solid seal configuration of the intermediate seal portion 129 (ie, where the attachment layers 105 , 107 are not attached) can result in a more flexible web 100 .

According to various embodiments, sealing portion 118 may include a narrow portion (eg, sealing portion 118 ) and a wide portion (eg, sealing portion 129 ). Seal portion 118 may bifurcate to form two seal portion bifurcations that define an intermediate seal portion 129 . This location where the seal portion 118 widens to the seal portion 129 may be located at the transition portion 127 . The width of the transition portion may be wider than the width of the sealing portion 129 . For example, the sealing portion 129 may have a width J. Transition 127 may widen from width J . The width J may be between 11/2 times and 10 times wider than the sealing portion 118 . For example, transition portion 127 may be five times wider than seal portion 118 . The transition can then narrow again to a width K above and below the transition region. Alternatively, where the sealing portion 118 is continuous, the transition portion 127 may widen to the full width of the transition region, and then narrow to a width J. FIG. Transition 127 may be concave when viewed from inflation chamber 120 . This can allow the transition to be smooth without being too sharp. Although in some embodiments sharp transitions can be used. According to various embodiments, the intermediate sealing portion 129 may be circular, elliptical, triangular, trapezoidal, polygonal, or any other shape. As shown in FIGS. 3A-3B , the intermediate sealing portion 129 may be circular. The intermediate seal portion 129 may be a seal between the first layer and the second layer. Alternatively, the intermediate sealing portion 129 may be an unattached portion of the first and second layers that positively seals the first and second layers on all sides. The sealing portion (such as the sealing portion 118 and/or the transition portion 127) is bounded.

According to various embodiments, a gradual transition may be used to reduce stress at the intermediate seal portion 129 . Transition 127 may reduce the tendency of intermediate seal portion 129 to separate due to stress exerted on membrane 100 . In various embodiments, membrane 100, whether formed as a container (eg, container 50) or used as an inflatable sheet, may have areas of increased pressure. The pressure may be generated by a jagged object contacting the membrane 100 , bending of the membrane 100 , or wrinkling of the membrane 100 causing an increase in pressure. Under such pressure increases, sharp transitions may cause stress risers that may cause tearing or separation of the seal or membrane 100 . An example of a sharp transition may be where intermediate seal portion 129 and seal portion 118 are positioned at 90 degrees relative to each other. In another example, the transition may be gradual, wherein a curve extends from seal 118 through transition 127 to seal 129 with a blunt curve on the inner portion of seal 129 . In some examples, there may be no interior portion of seal 129 . The widening can be a solid seal over the entire extent. In other cases, the sealing portion 129 may have an unattached interior bounded on each side by the sealing portion 129 .

According to various embodiments, an inner portion of the sealing portion 129 may include a hole 131 . The holes 131 can reduce or eliminate stress on the seal. The holes may allow the material within the seal 129 (whether such material includes attached or unattached layers) to bend and twist, thereby reducing the tendency of the seal to tear or separate.

According to various embodiments, the hole 131 may be located in a seal portion separate from the transverse seal. These seals can be completely surrounded by the air chamber. A seal within panel 183 is one example. The sealing portion may also be located between the transverse seals along the air chamber. The hole can be surrounded by a seal. The seal may enclose areas where the first layer and the second layer are not attached to each other, and the holes may be located in the unattached areas. The seal may enclose a region where the first layer and the second layer are sealed to each other, and the hole may be located in the sealed region. Holes may extend through both the first and second layers. The holes may include a first hole extending through the first layer and a second hole extending through the second layer and aligned with the first hole. The holes may be close to regions of the layer that are subject to elevated stress. The seal may be completely contained within the inflation chamber. The sealing portion may have opposing first and second sides, wherein the first side of the sealing portion is disposed within the first inflation chamber and the second side of the sealing portion is disposed within the second inflation chamber. The seal may be formed by heat sealing techniques. The seal can be formed using an adhesive. The holes may be bounded by portions of the seal pattern. The holes may be configured to reduce stress at the seal. The holes may be of sufficient size to vent gas from one side of the packaging element to the other. The aperture may comprise a plurality of apertures, and wherein the seal pattern surrounds each of the plurality of apertures.

According to various embodiments, the membrane 100 may have a plurality of pores 131 dispersed throughout the membrane 100 . Apertures 131 may provide one or more of stress relief (as described above) or ventilation. The hole 131 may be a through hole extending through the wall. Each hole 131 may be, for example, a single hole extending through a single surface (eg, a single layer or two layers fused at a seal line), or each hole 131 may be more than one hole. For example, hole 131 may be a first hole through first layer 105 that is generally aligned with a second hole through second layer 107 . In some embodiments, the holes may be misaligned with enough air between the layers to allow ventilation through the holes.

The holes may be configured such that they do not promote continuous tearing from each other or across significant portions of the flexible structure. For example, this means that a tear in one hole is less likely to propagate to the next hole, etc. This structure can be achieved by the position of the holes relative to each other, the position of each hole relative to another feature, or the shape of the holes. For example, the holes may be positioned such that the space between the holes is operable to prevent or limit subsequent tearing between the holes. For example, the space between the holes may be greater than twice the width of the holes, three times the width of the holes, or four times the width of the holes. The apparent shape of the holes can be shaped to allow the passage of air and ventilation, but the shape of the holes is not designed to facilitate separation of the chambers or enable the chambers to be separated. Furthermore, the holes can be designed to stretch out during inflation, and the width of the holes can be varied according to the required ventilation needs. In another example, the shape of the holes may be circular such that the hole shape is operable to prevent or limit subsequent tearing between the holes so that the holes do not form perforation lines. In another example, the holes are separated from each other by a sealing boundary such that the sealing boundary prevents or limits subsequent tearing between the holes.

According to various embodiments, the holes 131 may be used as vents to allow gas to circulate through the membrane 100 . For example, in embodiments where membrane 100 forms a bag or other sealed container, apertures 131 may form ventilation holes. For example, holes 131 may allow ethylene produced from organic materials contained therein to escape and allow fresh air to enter. These holes 131 may be of any shape. As shown in FIGS. 1-2 and 3E-3F , the hole 131 may be an elongated slit. The slits may have a width of zero or an insignificant width, such as a width with shape endpoints formed by razor cuts. The slit may be an elongated hole of appreciable width. The slits can be polygonal. The slits may have rounded ends as shown in Figure 3A, or the holes may have no sharp edges. The holes may have blunt edges. The holes may be "X" shaped or cross shaped as shown in Figure 3B.

According to various embodiments, intermediate sealing portion 129 may be configured to reinforce aperture 131 through layer 105 and layer 107 . As noted above, the intermediate seal portion 129 may be a solid seal over its entire area (see, for example, FIGS. eg Figures 3A-3B). The hole 131 may pass through a central portion of the intermediate sealing portion 129 . In this manner, the intermediate sealing portion 129 prevents or limits the hole 131 from piercing any of the adjacent inflation chambers 120 . Thus, the membrane 100 is operable to provide ventilation through the holes 131 and cushioning via the adjacent inflation chamber 120 .

As shown in FIGS. 3C-3D , the intermediate sealing portion 129 can withstand a force F during inflation, shipping, handling, packaging, storage, bending, folding, expanding (e.g., being loaded or overloaded as a container), or Other conditions to which the product is exposed cause stresses on the structure 100 . These forces may have a tendency to separate the permanent or non-permanent seal (holding the first and second layers of the flexible structure 100 together). These forces may also have a tendency to cause tearing in the inflation chamber at the various seals. Holes can relieve stress from these longitudinal forces. These forces F can twist the flexible structure around the hole, allowing the structure to shear, compress, or elongate under tension. The holes may allow locally increased twisting in this region, thereby relieving increased stress at the seal. This deformation can relieve increased stress at or near the various seals. These twists can reduce the likelihood of seal or wall damage. This prevents or limits any separation and/or tearing of the seal into the inflation chamber. The local deformation can increase the stress on the hole 131 that the surrounding intermediate sealing portion 129 can accommodate. Figure 3E shows the intermediate seal portion and aperture under tensile stress. Figure 3F shows the intermediate seal portion and hole under shear stress.

According to various embodiments, the holes may be of any shape including die cut holes. For example, the holes may be slits. A slit (i.e., a long cut forming a hole where the width of the hole is negligible compared to the length, and the slit terminates in a sharp transition on either side) can create stress on either end of the slit point, this can tend to tear the slit. The intermediate seal portion 129 can limit this tendency and prevent or limit the propagation of tears between adjacent holes and/or air chambers. The aperture may be circular, which may include circular, generally circular, oblong, elliptical, oval, or have generally curved boundaries and/or have sharp transitions that are constrained between sides . Circular hole 131 may exhibit reduced tear stress on the hole, but intermediate seal portion 129 may still provide isolation from inflation chamber 120 and increase strength to prevent hole 132 from tearing into inflation chamber 120 and Deflate the inflation chamber.

According to various embodiments, flexible structure 100 may include intermediate features. Intermediate features may be portions of the flexible structure 100 without chambers and/or with interrupted chambers to form functional elements on the flexible structure. These functional elements may include removable panels, openings, windows, flat panels, printable panels, handles, attachment features, and the like. In one example, the intermediate feature may be an access panel 183 . The access panel may include a detachable border 185 that can be manipulated to separate from the rest of the flexible structure 100 . Such a separable boundary 185 may define an opening through the flexible structure 100 and covered by the access panel 183 . Separable boundary 185 may be any detachable structure. For example, the separable border 185 may be a perforated rim, or a mixture of a perforated rim and a resealable rim. The perforated edge can be operable to be easily torn from the flexible structure 100 at the separable boundary 185 . In another example, the separable boundary 185 may be a resealable edge by utilizing, for example, a zipper seal (eg, a Ziploc-shaped closure). In another example, separable boundary 185 may be an adhesive seal, sometimes referred to as a pressure sensitive seal. In each of these examples, access panel 183 can be opened by separating separable boundary 185 from the rest of flexible structure 100 . A separable boundary can take any form or shape. The separable boundary can be enclosed or be of an open configuration with free ends. For example, the separable boundary can be rectangular, circular, triangular, linear, etc. The separable border may allow the panel 183 to open like a door and allow the contents to be removed from the interior of the container 50 . For example, grapes can be removed.

Separable boundary 185 may be isolated from chamber 120 . For example, seal 184 may be substantially parallel to separable boundary 185 or generally along separable boundary 185 by some offset distance. This offset may allow seal 184 to separate from chamber 120 . In various embodiments, the sealing portion 184 may be continuous with the sealing portion 112 . In other embodiments, the sealing portion may be separate from the sealing portion 112 and located inside the sealing portion 112 . The separable boundary 185 may be offset from the exterior of the first or second wall (eg, edges 102 , 106 , 104 , 108 or seals 141 , 142 ). Separable boundary 185 may begin and end at a portion inside membrane 100 . In this way, the perforations do not tear to the edge of the film 100, nor does the separable boundary 185 completely separate the different parts of the structure. However, other areas of weakness as described above may do so.

According to various embodiments, the clamping portion may extend from the panel 183 . The clamping portion may be a separate flap protruding from the surface of the flexible structure 100 at the panel 183 . Alternatively, the clamping portion may be defined by a pre-separated portion of the separable boundary 185 . Alternatively, the clamping portion may be defined by a perforated easily detachable portion. The clamping portion can be operable to receive a force and transmit the force through the panel 183 to the detachable boundary 185 such that the panel 183 is at least partially detached from the flexible structure 100 .

According to various embodiments, the panel 183 may include a hinged portion. The hinged portion may be defined by at least one edge of the panel 183 that is continuous with the remainder of the flexible structure 100 . For example, at least one edge of panel 183 does not have a separable border or any separating feature.

The separable boundary 185 may extend into the same chamber or divide the same chamber into two parts. In some embodiments, the door cavity has a channel to enable the door to be inflated. In some embodiments, the door does not have an inflation chamber, but may have a flat window for viewing, or a panel for printing a label on. According to various embodiments, as shown in FIG. 1 , the seal 187a or 187b may be a longitudinal seal or a substantially longitudinal seal (eg, may have a longitudinally oriented component and a transversely oriented component) interrupting one or The plurality of chambers 120d or such that one or more chambers 120n, 120p extend beyond the interruption. The discontinuity may prevent the one or more chambers 120d from extending the lateral width of the flexible structure 100 . The extension may allow the new chamber 120n, 120p to resume after interrupting the first chamber 120d, thereby allowing the inflated cushion to extend the remaining lateral distance across the flexible material. Small gaps 187c may be located between interrupted chambers and continuous chambers. In this manner, some of the chambers 120 may extend from end 124 to end 122 the lateral width of the flexible structure. Some chambers 120n, 120p may extend only from or to seal 187a, or some chambers 12Od may only extend to 187b.

According to various embodiments, the sealing portion 187b may terminate laterally to the chamber 120d at the intermediate sealing portion 128 . Seal 187 may intersect transverse seal 118c. Intermediate seal 128 may be a fold feature between separate walls of container 50 . The intermediate seal portion 128 may not be continuous to the seal portion 187b, and the seal portion 187b may be continuous. Thus, intermediate seal 128 may allow chamber 120 to inflate on both lateral sides of intermediate seal 128, while seal 187b may prevent or limit chamber 120d from extending beyond seal 187b. Intermediate seal 128 and seal 187 may be positioned at any lateral position along flexible structure 100 . For example, they may be positioned along the centerline so that the half of the flexible structure 100 can be folded over on itself. In another example, they may be positioned at quarters along the lateral distance, allowing the flexible structure to be folded in two to form the container 50 .

According to various embodiments, the seal 187a may be a longitudinal seal that also intersects the transverse seal 118c. In various embodiments, the transverse seal 118c may discontinuously cross the intersection of the seal 187a. After passing over the intersection of seals 187a and 118c, only wide portion 131 of seal 118c exists. The discontinuous configuration of transverse seal 118c may provide passage 119 extending between chamber 120 and chambers 120n, 120p. Similar channels may extend between successive chambers 120n, 120p in the longitudinal direction. The seal 187a may be a longitudinal seal defining a chamber 120n between the panel 183 and the intermediate seal 128 . In this embodiment, the second seal may terminate in chamber 120n. Alternatively, seal 187a may be a seal defining an edge of panel 183 proximate intermediate seal 128 . In either embodiment, the seal portion 187a may be continuous with the seal portion 184 to define only the panel or to define a panel with the cavity 120n. In one embodiment, panel 183 may extend the entire width of one wall of container 50 . In other embodiments, panel 183 may extend only a portion of the lateral distance on one wall of container 50, panel 183 being bounded on one or more sides by an air chamber (eg, chamber 120n). In various embodiments, channel 119 may allow chamber 120p within panel 183 to inflate. In this embodiment, the interior of the panel is in fluid communication with the inflated region such that the panel has the inflated region and the resulting protective function.

By utilizing intermediate seals 187a and 187b and/or other seals to create breaks in chambers 120d and/or 120n, the process of tearing panel 183 from opening at perforation 185 does not cause adjacent inflation chambers 120, 120n or 120p deflated.

As shown in these exemplary embodiments, the flexible structure may include any of a variety of intermediate features, of which panel 183 is an example. Channel 119 and intermediate seals (eg, 187a, 187b) may allow channel 120 to cease and continue on either side of the intermediate feature. Channel 119 may also provide inflation for the middle feature if it is not bounded on all sides like panel 183 . Another example of an intermediate feature is shown in FIGS. 10-12 as an uninflated flat surface 509 . Such a flat surface 509 may be incorporated into any of the embodiments discussed herein. For example, panel 183 may be replaced by removing channel 120p from the panel and forming a transverse seal (eg, 118c) below the panel to form a continuous panel. In various embodiments, a chamber boundary may be formed around the enlarged uninflated portion. This uninflated portion may be large enough to form a viewing window or provide product information. For example, such uninflated portion may be greater than 1/2 inch by 2 inches. In various examples, such uninflated portions may be larger than other discontinuities between chambers, such as the widened seal portions described above. However, the uninflated portion may also be a seal between layers that is large enough to serve more than just a sealing function. In this way, the flat surface 509 would not be able to be inflated, but could receive printing, labels or other indicative information. The flat surface 509 may also or alternatively be transparent, thereby providing a window through the flexible membrane 100 . Such an information presentation surface or information window may be applied in the flexible film 100 in its flat state (as a divider) or in its formed state (such as a container as described herein).

According to various embodiments, the flexible structure 100 may include a handle 150 . The handle may be any area or opening operable to place a user's finger through itself to hold the product. Handles may be provided by forming areas of weakness, or cutting holes through the flexible structure 100 (either in flat form or structural form (eg container 50)). The handle 150 may be located near the lateral edge 149 of the flexible structure 100 . Handle 150 may be defined by one or more sealed portions of flexible structure 100 operable to function as a handle. In one example, the outer handle seal 151 may be positioned proximate to the lateral edge/seal 149 or at other desired locations. In various embodiments, the separate outer handle seal 151 may be positioned generally symmetrically about the longitudinal centerline 128, or in other useful configurations. The handle 150 may include an inner handle seal 153 located within the one or more handle seals 151 . The space between the outer handle seal 151 and the inner handle seal 153 may define a detachable portion of the handle. In various embodiments, the separable portion may be a line of weakness 155 that may extend at least partially around the space between the outer handle seal 151 and the inner handle seal 153 . The line of weakness 155 can be broken, exposing a hole through the membrane. When the symmetrical handles 150 overlap, the apertures may align, forming a portion of the container 50 that can be grasped as a handle.

As mentioned above, the flexible structure may be used as a flat configuration or it may be formed as a container 50 (see eg FIG. 4 ). Container 50 may be formed from two separate pieces of flexible structure 100 sealed together, or container 50 may be formed from a single piece of flexible structure 100 folded and sealed together as shown in FIGS. 2A and 2B . Container 50 may also be constructed from any number of sheets of flexible structure 100 forming more than two walls as required in various applications. Figure 2A shows a schematic diagram of a flexible structure being folded, according to various embodiments. As mentioned above, the flexible structure 100 can be folded along the intermediate seal 128 . Such intermediate seals may be in any location and in any number such that the flexible structure 100 may be folded by folding any number of times. In various embodiments, flexible structure 100 may be folded along a centerline, as shown in the example of FIG. 2A . Folding the flexible structure 100 in this manner may allow the edges 102, 106 and 104, 108 to be aligned. As the flexible structure 100 is folded, the first and second walls may be sealed along a plurality of seals. For example, as shown in FIG. 2B , the seals may include one or more of a top seal 145 , an outboard longitudinal seal 142 , an inboard longitudinal seal 141 , and a bottom seal 159 . A second transverse seal similar to seal 145 may additionally be formed along transverse edge 149 . The second transfer seal may be a replacement seal for seal 145 . In some embodiments, the handles may also be sealed together at 150 . These seals may be formed after the product or other contents have been disposed in the container 50 . The seal may be formed using mechanical attachment (eg, zipper-type attachment), heat, adhesives, or any other means known in the art. The first and second walls of container 50 may be sealed along an adhesive seal as shown in Figure 2A. For example, the seal on the first wall 50a may include one or more of the seals 141a, 142a, 159a, 150a, and 145a. The seal on the second wall 50b may include one or more of the seals 141b, 142b, 159b, 150b, and 145b. The seal may form a boundary around the unattached portion that defines the interior 147 of the container 50 . Interior 147 may receive product or other contents. The seals 141a, 142a, 159a, 150a, and 145a, 141b, 142b, 159b, 150b, and 145b can be operable to connect walls formed from multiple film layers. These seals therefore do not have to extend between the layers 105, 107, but can. These seals may extend only from layer 105 to layer 105, or from layer 107 to layer 107, thereby forming the walls of the container. It should be noted that, for example, where an adhesive is used, the adhesive may be disposed in each of the "a" and "b" positions, for example, 141a and 141b. The adhesive may be any kind of adhesive such as, but not limited to, ultraviolet (UV) curable adhesives. However, the adhesive may be placed on only one of these locations (eg 141a), and when the structure 100 is folded, 141a may be aligned with 141b such that the seal is formed in both locations. This also applies to 142a, 142b, 159a, 159b and 145a, 145b.

Figure 4 illustrates a packaged product contained within an inflated flexible structure according to various embodiments. As shown, a number of packaged products 300 may be separated from one another by a flexible structure, shown here as a container 50 . Chamber 120 provides protection for product 300 . Apertures 131 provide ventilation for product 300 . Tab 187 provides access to product 300 as described above. The handle 150 allows the product 300 to be carried.

According to various embodiments, any product may be packaged with the flexible structure 100 . Additionally, packaging certain products with the flexible structure 100 can significantly extend the life of the product. For example, a product having viscoelastic properties can be protected by the flexible structure 100, thereby reducing the damage that is often caused to the product due to its structural properties. Since damage also has a tendency to release certain gases, such as ethylene, ventilation in the flexible structure 100 can further benefit the product by allowing the gases to circulate away. This is desirable in the case of cleamer fruits, which continue to ripen after picking and are therefore prone to accelerated ripening due to ethylene. Leaves, such as lettuce, are also susceptible to this ripening process. Reduces the impact of enzyme-producing genes within the product by reducing scarring/damage to the product and venting ethylene. This reduces the activity of the enzyme causing the maturation reaction. Products that may fall into these categories may include grapes, apples, lettuce, potatoes, onions, bananas, and others known in the art. Each container 50 can hold 1/2 lb of fruit to 5 lbs of fruit. For example, each container can hold about 1/2 lb to 2lbs of fruit.

5A-5B illustrate groups of packaged products contained within a plurality of inflated flexible structures according to various embodiments. As shown, the flexible structure 100 may be formed as a container 50a, 50b, 50c. These containers can be packaged together into a single bundle. Figure 5A shows two containers 50a, 50b joined together, where a single structural handle 51 provides support for the handle. The structural handle 51 can be cardboard, plastic or any other known shipping material that can hold multiple containers together and add support to the handle. The structural handle 51 can also be used as a labeling surface for identification and information purposes. Figure 5B shows a series of containers 50a, 50b, 50c joined together in a tree. In various embodiments, flexible structures can be filled and sealed without separation from each other. Figure 1 shows two connected flexible structures 100a, 100b. By filling and sealing the connected flexible structure, a series of connected containers 50a, 50b, 50c can be formed. This can simplify the shipping and procurement aspects of the industry. Alternatively, the structures may be detached and then reconnected via the structure handles 51a, 51b, 51c.

Packaged products can then be shipped, contained or displayed in bulk containers. 6A-6B illustrate packaged products contained within a plurality of inflated flexible structures and stored in crates, according to various embodiments. With containers 50, such as shown in FIG. 6B, to protect the products, the products can be stacked deeper in the crate. In this way, products can be shipped, contained and displayed in larger containers, thereby allowing increased efficiency in the industry.

Figure 7 shows an example of an inflatable package sealing device 101 for sealing an inflatable flexible structure. The inflation and sealing device 101 is operable to convert the flexible structure 100 of uninflated material into a series of inflation pads or cushions through the inflation chamber 120 . As shown in Figure 7, the uninflated web 100 can be an uninflated material supplied in bulk quantities. For example, the uninflated flexible structure 100 may be provided in bulk form on a roll to be inflated and sealed by the device 101 . For example, a bulk quantity of uninflated material may be a roll of material 134 . The flexible structure 100 may be wrapped around the inner support tube 133 .

The inflation and sealing device 101 may include a bulk material support 136 . Bulk quantities of uninflated material may be supported by bulk material supports 136 . For example, the bulk material support may be a tray operable to retain uninflated material, such retention may be provided by a fixed surface or a plurality of rollers. To hold the roll of material, the tray can be concave around the roll of material, or the tray can be convex with the roll of material suspended above the tray. The bulk material support may comprise a plurality of rolls suspending the web. The bulk material support may include a single roller that accommodates the center of the roll of web material 134 . The roll of material 134 may be suspended above the bulk material support 136 , for example the roll of material 134 may be suspended on a spindle passing through the core 133 of the roll of material 134 . Typically, the core of the roll is made of cardboard or other suitable material.

According to various embodiments, the nozzles may not only inflate the web 100 at the transverse edges, but may also engage inflation channels at any transverse distance between the longitudinal edges; i.e., inflate and seal Device 101 fills the central channel with chambers located on both lateral sides of the inflation channel. The web 100 may be rolled off the material support 136 and onto the guides 138 in such a manner that such central inflation channel 114 of the flexible structure 100 is aligned with the nozzles in the inflation region 142 .

The inflation and sealing device 101 may be configured to continuously inflate the web 100 as the web 100 is unrolled from the roll 134 . Roll 134 includes a plurality of inflation chambers 120 arranged in series. To begin fabricating an inflation pad from web material 100, inflation opening 116 of web 100 is inserted around inflation components such as inflation nozzles in inflation region 142. The web 100 is advanced over the inflation nozzle, with the chamber 120 extending transversely relative to the inflation nozzle and the outlet on the inflation nozzle. As the web 100 advances along the material path in the longitudinal direction, outlets direct fluid from the nozzle body into the chamber 120 in order to inflate the chamber 120, which outlets can be arranged, for example, on the radial sides of the nozzle and/or or on the upstream end. The inflated web 100 is then sealed by the sealing mechanism in the sealing area 174 to form a series of inflation pads or cushions.

The inflation nozzles inject fluid, such as pressurized air, into the uninflated web material along the fluid path through nozzle outlets, thereby inflating the material into inflation pads or cavities 120 . The inflation nozzle can include a nozzle inflation passage fluidly connecting a fluid source with a nozzle outlet. It will be appreciated that in other configurations the fluid can be other suitable pressurized gases, foams or liquids. The web 100 is fed through inflation nozzles which direct the web to an inflation and sealing assembly 103 . The web 100 is advanced or driven through the inflation and sealing device 101 in a downstream direction along the material path by a drive mechanism such as a drive or seal drum or drive rollers.

After being fed through the web feeding area 164, the first layer 105 and the second layer 107 are sealed together by the sealing assembly and exit the sealing drum. The sealing drum may include a heating element (eg, a thermocouple) or other type of welding or sealing element that melts, fuses, joins, bonds, or joins the first layer 105 and the second layer 107 together. The web 100 is continuously advanced along the material path through the sealing assembly and through the sealing drum at the sealing area 174 to form a continuous longitudinal seal along the web by sealing the first layer 105 and the second layer 107 together, And leave the sealed area. In various embodiments, the inflation and sealing apparatus 101 also includes a cutting assembly for severing the web from the inflation nozzle when using an inflation channel that is received around the longitudinal inflation nozzle and is closed.

According to various embodiments, the inflation and sealing device may have more than one strap. For example, one belt may drive multiple rolls, while a second belt may press the web against the sealing drum. In various embodiments, the inflation and sealing device may be strapless. For example, a sealing drum may press the web against a stationary platform and simultaneously drive the web through the inflation and sealing device.

According to various embodiments, these and other components used in inflation and sealing device 101 may be constructed, positioned, and operated as disclosed in any of the various embodiments described in the incorporated documents, which and Other components include, but are not limited to, nozzles, inflatable seal assemblies and drive mechanisms, and individual components thereof or related systems, as incorporated in documents such as U.S. Patent No. 8,061,110; U.S. Patent No. 8,128,770; U.S. Patent Publication No. 2014 /0261752; and US Patent Publication No. 2011/0172072, each of which is incorporated herein by reference. Each of the embodiments discussed herein may incorporate and be used with the cited reference and/or other inflation and sealing device. For example, any mechanism discussed herein or incorporated in the document may be used to inflate and seal the flexible mechanism 100, as may the web or film materials described in the incorporated document.

As mentioned above, the flexible structure can be heat sealed or adhesively sealed. Furthermore, the flexible structure can be folded to form the first and second walls of the container, which can be sealed together by heat sealing or adhesive sealing. Alternatively, the first wall and the second wall may be formed as separate flexible structures which may be sealed together by heat sealing or adhesive sealing. As such, the above-described mechanisms and processes for heat sealing are not intended to be limiting in scope but merely to provide an explanation of exemplary processes and devices for performing the task. The sealed flexible structure or walls may be bonded to form the container by any method known in the art.

According to one embodiment, a portion of an inflatable container 501 may include an inflatable chamber 501 , as shown in the example of FIG. 8 showing a section through the inflation chamber. The length of the inflatable chamber 501 can vary to support various shapes. The inflatable chamber 501 can have a length 502 that can be adapted to form either side of a container (eg, a product container). Length 502 may increase or decrease depending on the shape. For example, length 502 may be long enough to wrap around the perimeter of the designed product volume. The outer surface 503 can contact the product and separate each package from each other. The interior volume 504 of the structure may contain inflation gas. The gas can add rigidity to the chamber 501, thereby doubling the rigidity as a structural member. The inflated chamber 501 may also act as a thermal barrier to extend the product shelf life of the product. Seals 505 may be welded together using a heating element. A series of holes 506 may be provided through the seal 505 so that the product may be vented through the holes or the product may be watered down through the holes during transport and at the point of sale. The holes may be close together but have rounded ends in order to limit or prevent tear propagation between the holes.

Figure 9 illustrates a sheet of film embossed to form a structured shape, according to various embodiments. The two layers can be sealed and air trapped between the two layers. The assembly can be used as a wall or divider of a container for protecting the contents (eg product). Multiple sheets can be combined to form a container. The chamber end 503 may be configured to seal the end of the chamber. As shown in Figure 9, the two sheet halves can be formed separately and then heat sealed together.

According to various embodiments, as shown in FIGS. 10A-10B (showing a packaging structure formed as a container), the chamber 501 may be formed as a hoop defining an interior storage area of the container. In various embodiments, the flat flexible structure can be bent into the circular shape of FIGS. 10A-10B . Inflation channel 514 may extend proximate to handle 507 . End caps 506 may be applied to accommodate the sides of the container. Intermediate feature 509 may be formed on one side of the container by interrupting chamber 501 . Features can be flat tabs, windows, accessor locations, etc. Feature 509 may be flattened to reduce label distortion or to allow transmission of light through the window. A handle 507 may be included as a termination location for the chamber 501 . The chamber end 503 may be positioned at the base of the container. Side panels 505 may be sealed to the flexible structure forming chamber 503 . Separate side panels may provide a cylindrical shape to the flexible structure forming chamber 503 .

According to various embodiments, the chamber can be arranged to provide a variety of shipping configurations, as shown in FIGS. 10A-10B which illustrate alternative packaging configurations. FIG. 10B shows the chamber vertically or perpendicularly to the handle 507 . The fold lines shown in the sidewalls are formed by changing the structure from a flat form to a three-dimensional form. FIG. 11 shows the chamber being horizontal or parallel to the handle 507 .

Any and all references specifically indicated in the specification of this application are hereby expressly incorporated by reference in their entirety. As used herein, the term "about" should roughly understand the corresponding number and a certain range of numbers. Moreover, all numerical ranges herein should be understood to include each integer within the range.

The various embodiments discussed herein provide a cost-competitive excellent structure capable of replacing corrugated cardboard. Various embodiments herein enable water drainage during cleaning and packaging of products and improve the quality of the final product. Additionally, various embodiments discussed herein increase manufacturing efficiency. For example, various embodiments discussed herein can be provided as pre-inflated "bags on rolls" for easy, automatic and compact release from rolls, or various embodiments discussed herein can be provided as unfilled bags on rolls. Inflated material that is ready to be inflated and sealed in place so that the shipping volume of the packaged product is reduced. Various embodiments discussed herein enable product packaging to simplify printing and/or advertising on its own. Various embodiments discussed herein provide a protective barrier that minimizes damage to products in transit. Since product spoilage is directly related to scarring and the capture of certain gases, various embodiments disclosed herein are able to address all of these issues and extend the life of the product.

Claims (56)

CLAIMS 1. An inflatable packaging element comprising: a first film layer and a second film layer, the second film layer is superimposed on the first film layer; A sealing part pattern, the sealing part pattern includes a plurality of sealing parts, and the plurality of sealing parts seal the first film layer and the second film layer to each other, so that the first film layer and the second film layer an inflation chamber is defined between the two membrane layers, the inflation chamber is inflatable with a fluid and configured to contain the fluid; wherein an aperture extends through at least one of the first membrane layer or the second membrane layer; and wherein the seal pattern separates opposite sides of the aperture from the inflation chamber. 2. The inflatable packaging element of claim 1, wherein the aperture is surrounded by the seal. 3. The inflatable packaging element of claim 2, wherein the seal encapsulates a region where the first and second film layers are not attached to each other, and wherein the aperture is located at in the unattached region. 4. The inflatable packaging element of claim 2, wherein the seal encloses an area where the first film layer and the second film layer are sealed to each other, and wherein the aperture is located at the in the sealed area described above. 5. The inflatable packaging element of claim 1, wherein the aperture extends through both the first film layer and the second film layer. 6. The inflatable packaging element of claim 5, wherein the aperture comprises: a first aperture extending through the first membrane layer; and A second hole extends through the second film layer and is aligned with the first hole. 7. The inflatable packaging element of claim 1, wherein the aperture is adjacent an area of the film layer that is subject to elevated stress. 8. The inflatable packaging element of claim 1, wherein the seal is completely contained within the inflation chamber. 9. The inflatable packaging element of claim 1, wherein the sealing portion has opposing first and second sides, and wherein the first side of the sealing portion is disposed on within the first inflation chamber and the second side of the seal is disposed within the second inflation chamber. 10. The inflatable packaging element of claim 1, wherein the seal is formed by heat sealing techniques. 11. The inflatable packaging element of claim 1, wherein the seal is formed using an adhesive. 12. The inflatable packaging element of claim 1, wherein the aperture is defined by a portion of the seal pattern. 13. The inflatable packaging element of claim 1, wherein the aperture is configured to reduce stress at the seal. 14. The inflatable packaging element of claim 1, wherein the holes are of sufficient size to vent gas from one side of the packaging element to the other. 15. The inflatable packaging element of claim 1, wherein the aperture comprises a plurality of apertures, and wherein the seal pattern surrounds each aperture of the plurality of apertures. 16. The inflatable packaging element of claim 15, wherein the pattern of seals includes a plurality of seals separated from each other, each of the intermediate seals surrounding the One of many holes. 17. The inflatable packaging element of claim 1, wherein the first film layer and the second film layer form a first wall, and wherein the inflatable packaging element further comprises a second wall, the The second wall is connected to the first wall to define a bag having a bag interior. 18. The inflatable packaging element of claim 17, further comprising an agricultural product contained within the bag interior. 19. The packaged product of claim 17, wherein the first film layer and the second film layer form a continuous wall, and wherein the continuous wall is formed by folding the continuous wall in half in a c-fold. the first wall and the second wall. 20. The packaged product of claim 17, wherein the first wall includes an access panel separable from the remainder of the first wall to provide access to the interior of the bag . 21. An inflatable packaging element comprising: a first film layer and a second film layer, the second film layer is superimposed on the first film layer; a pattern of seals, the pattern of seals comprising a plurality of seals sealing the first film layer and the second film layer to each other to define an inflation chamber between the second film layer, the inflation chamber is inflatable with a fluid and configured to contain the fluid; wherein an aperture extends through at least one of the first membrane layer or the second membrane layer; and wherein the seal pattern separates opposite sides of the aperture from the inflation chamber. 22. The inflatable packaging element of claim 21, wherein the aperture is surrounded by the seal. 23. The inflatable packaging element of claim 22, wherein the seal encloses a region where the first and second film layers are not attached to each other, and wherein the aperture is located at in the unattached region. 24. The inflatable packaging element of claim 22, wherein the seal encloses an area where the first and second film layers are sealed to each other, and wherein the aperture is located at the in the sealed area described above. 25. The inflatable packaging element of claim 21, wherein the aperture extends through both the first film layer and the second film layer. 26. The inflatable packaging element of claim 25, wherein the aperture comprises: a first aperture extending through the first membrane layer; and A second hole extends through the second film layer and is aligned with the first hole. 27. The inflatable packaging element of claim 21, wherein the aperture is adjacent to an area of the film layer that is subject to elevated stress. 28. The inflatable packaging element of claim 21, wherein the seal is completely contained within the inflation chamber. 29. The inflatable packaging element of claim 21, wherein the sealing portion has opposing first and second sides, and wherein the first side of the sealing portion is disposed on within the first inflation chamber and the second side of the seal is disposed within the second inflation chamber. 30. The inflatable packaging element of claim 21, wherein the seal is formed by heat sealing techniques. 31. The inflatable packaging element of claim 21, wherein the seal is formed using an adhesive. 32. The expandable packaging element of claim 21, wherein the aperture is defined by a portion of the seal pattern. 33. The inflatable packaging element of claim 21, wherein the aperture is configured to reduce stress at the seal. 34. The inflatable packaging element of claim 21, wherein the holes are of sufficient size to vent gas from one side of the packaging element to the other. 35. The expandable packaging element of claim 21, wherein the aperture comprises a plurality of apertures, and wherein the seal pattern surrounds each aperture of the plurality of apertures. 36. The inflatable packaging element of claim 25, wherein the pattern of seals includes a plurality of seals spaced apart from each other, each of the intermediate seals enclosing one of the plurality of holes. 37. The inflatable packaging element of claim 21, wherein the first film layer and the second film layer form a first wall, and wherein the inflatable packaging element further comprises a second wall, the The second wall is connected to the first wall to define a bag having a bag interior. 38. The expandable packaging element of claim 27, further comprising an agricultural product contained within the bag interior. 39. The packaged product of claim 27, wherein the first film layer and the second film layer form a continuous wall, and wherein the continuous wall is formed by folding the continuous wall in half in a c-fold. the first wall and the second wall. 40. The packaged product of claim 27, wherein the first wall includes an access panel separable from the remainder of the first wall to provide access to the interior of the bag . 41. A packaged product comprising: A flexible cushion comprising a first film layer and a second film layer sealed together by a seal to cooperatively form a wall, wherein: the seal defines an inflation chamber between the first film layer and the second film layer, the inflation chamber is inflatable with a fluid and configured to contain the fluid; and a plurality of holes extending through both membrane layers thereby providing ventilation through the wall; and An agricultural product adjacent the wall, cushioned by the inflation chamber, and ventilated through the aperture. 42. A packaged product according to claim 41, wherein the inflation chamber comprises a plurality of inflation chambers. 43. A packaged product according to claim 42, wherein the one or more seals connecting the first film layer and the second film layer define an inflation region, the inflation region being in contact with the The inflation chamber is in fluid communication, wherein the inflation region is configured to receive an inflation nozzle and direct fluid from the inflation nozzle into the inflation chamber. 44. A packaged product according to claim 41, wherein the plurality of apertures extend through both the first film layer and the second film layer. 45. A packaged product according to claim 41, wherein the plurality of apertures are located outside the inflation chamber. 46. The packaged product of claim 41, wherein the plurality of apertures are configured to reduce stress at the seal. 47. A packaged product according to claim 41, wherein the plurality of holes are of sufficient size to vent gas from one side of the wall to the other. 48. A packaged product according to claim 41, wherein: the wall is a first wall, and the flexible cushion further includes a second wall connected to the first wall to define a pocket having a pocket interior; and The agricultural product is located within the bag interior. 49. A packaged product according to claim 48, wherein the first wall and the second wall are joined on three sides to define the pouch interior. 50. A packaged product according to claim 49, wherein the first wall and the second wall are joined on a fourth side to enclose the pouch interior. 51. A packaged product according to claim 48, wherein the second wall is defined by the third and fourth film layers joined to each other at the other one or more seals, the other one or more A seal defines a further inflation chamber between the third membrane layer and the fourth membrane layer, the other inflation chamber being inflatable with a fluid and operable to contain the fluid. 52. The packaged product of claim 48, wherein the first film layer and the second film layer form a continuous wall, and wherein the continuous wall is formed by folding the continuous wall in half in a c-fold. the first wall and the second wall. 53. The packaged product of claim 48, wherein the first wall includes an access panel separable from the remainder of the first wall to provide access to the interior of the bag . 54. A packaged product according to claim 48, wherein the access panel is separable from the remainder of the first wall at a boundary defined by a perforated edge or a resealable edge. 55. The packaged product of claim 48, wherein the agricultural product comprises grapes. 56. A packaged product according to claim 48, wherein the first wall and the second wall are attached to each other with an adhesive.