High-speed apparatus and method for forming inflated chambers

1. A method for inflating an inflatable web, the inflatable web comprising two sheets having inner surfaces sealed to each other with intermittent seals defining a series of inflatable chambers, the inflatable web having opposite longitudinal edges, each inflatable chamber having an inflation port adjacent one of the longitudinal edges, the intermittent seals terminating a distance from one edge of the web to form an unsealed edge portion or skirt of the web, the method comprising the steps of:

conveying the inflatable web along a path of travel substantially parallel to the longitudinal edges of the inflatable web;

positioning an inflation device comprising an inflation element such that the inflation element intervenes between the edge portions of the two sheets, and discharging gas from the inflation element into each inflation port in turn as the inflatable web is conveyed along the path of travel such that each inflatable chamber is inflated with gas;

sealing the two sheets together to seal closed the inflation ports after inflation of the inflatable chambers by the inflation device;

detecting the transverse position of the inflatable web with respect to the inflation device using a tracking sensor having a contact sensor that is movable along the transverse direction of the web and is positioned between the sheets of the skirt and arranged to be contacted by ends of the intermittent seals as the inflatable web is conveyed, the contact sensor retaining contact with the ends of the intermittent seals and moving transversely in response to transverse movement of the web; and

continually adjusting a transverse position of the inflatable web with respect to the inflation, on the basis of an output of the tracking sensor, device so as to maintain said transverse position within a predetermined range.

2. An apparatus for inflating an inflatable web, the inflatable web comprising two sheets having inner surfaces sealed to each other with intermittent seals defining a series of inflatable chambers, the inflatable web having opposite longitudinal edges, each inflatable chamber having an inflation port adjacent one of the longitudinal edges, the intermittent seals terminating a distance from one edge of the web to form an unsealed edge portion or skirt of the web, the apparatus comprising:

a web conveying system for conveying the inflatable web along a path of travel substantially parallel to the longitudinal edges of the inflatable web;

an inflation device comprising an inflation element arranged to intervene between the sheets of the skirt, the inflation element defining a gas outlet port through which gas is discharged into each inflation port in turn as the inflatable web is conveyed along the path of travel;

a sealing device for sealing the two sheets together to seal closed the inflation ports after inflation of the inflatable chambers by the inflation device;

the inflation device comprising a tracking sensor operable to detect the transverse position of the inflatable web with respect to the inflation device, the tracking sensor including a contact sensor movable along the transverse direction of the web and positioned between the sheets of the skirt and arranged to be contacted by ends of the intermittent seals as the inflatable web is conveyed, the contact sensor retaining contact with the ends of the intermittent seals and moving transversely in response to transverse movement of the web; and

a web tracking system which is, on the basis of the output of the tracking sensor, structured and arranged to continually adjust a transverse position of the inflatable web with respect to the inflation device so as to maintain said transverse position within a predetermined range.

3. The apparatus of claim 1 , wherein the apparatus includes a roll mounting arrangement structured and arranged for rotatably mounting a roll of the inflatable web such that the roll is movable back and forth in opposite first and second directions, respectively, parallel to a rotation axis of the roll, and wherein the web tracking system is structured and arranged to position the roll of the inflatable web in said first and second directions, thereby effecting adjustment of the transverse position of the inflatable web.

4. The apparatus of claim 3 , wherein the web tracking system comprises a first actuator structured and arranged to apply a force in said first direction to a first end of the roll of inflatable web.

5. The apparatus of claim 4 , wherein the web tracking system further comprises a second actuator structured and arranged to apply a force in said second direction to a second end of the roll of inflatable web.

6. The apparatus of claim 5 , wherein the web tracking system further comprises a controller structured and arranged to command one or the other of the first and second actuators to adjust the position of the roll of inflatable web in the first or second direction.

7. The apparatus of claim 6 , wherein the first and second actuators comprise pneumatic cylinders, and the web tracking system further comprises a controllable valve receiving pressurized air from a source and selectively positionable in either a first position in which the valve supplies air to the first actuator or a second position in which the valve supplies air to the second actuator.

8. The apparatus of claim 7 , further comprising an air-operated web tension control device that receives pressurized air from the source and acts on the inflatable web to regulate tension thereof.

9. The apparatus of claim 1 , wherein the inflation device comprises a pair of guides between which the edge portions of the two sheets are received.

10. The apparatus of claim 9 , wherein the inflation element is positioned between the guides such that the edge portion of one sheet passes through a channel defined between one guide and one side of the inflation element and the edge portion of the other sheet passes through another channel between the other guide and an opposite side of the inflation element.

11. The apparatus of claim 1 , wherein the inflation element is shaped generally as a vane.

12. An apparatus for inflating an inflatable web, the inflatable web comprising two sheets having inner surfaces sealed to each other in a pattern defining a series of inflatable chambers, the inflatable web having opposite longitudinal edges, each inflatable chamber having an inflation port adjacent one of the longitudinal edges, the inflation ports being defined by intermittent seals between the two sheets, and the two sheets having unsealed edge portions that extend beyond the inflation ports of the inflatable chambers, the apparatus comprising:

a web conveying system for conveying the inflatable web along a path of travel substantially parallel to the longitudinal edges of the inflatable web;

an inflation device comprising an inflation element arranged to intervene between the edge portions of the two sheets, the inflation element defining a gas outlet port through which gas is discharged into each inflation port in turn as the inflatable web is conveyed along the path of travel;

a sealing device for sealing the two sheets together to seal closed the inflation ports after inflation of the inflatable chambers by the inflation device; and

a web tracking system structured and arranged to continually adjust a transverse position of the inflatable web with respect to the inflation device so as to maintain said transverse position within a predetermined range;

wherein the inflation device comprises a pair of guides between which the edge portions of the two sheets are received, wherein the inflation element is positioned between the guides such that the edge portion of one sheet passes through a channel defined between one guide and one side of the inflation element and the edge portion of the other sheet passes through another channel between the other guide and an opposite side of the inflation element; and

wherein the guides are mounted on the inflation device so as to be movable toward and away from each other between a web-threading position in which the guides are spaced relatively farther apart and the channels are relatively wide to facilitate threading of the edge portions through the channels, and a production position in which the guides are spaced relatively closer together and the channels are relatively narrow.

13. An apparatus for inflating an inflatable web, the inflatable web comprising two sheets having inner surfaces sealed to each other in a pattern defining a series of inflatable chambers, the inflatable web having opposite longitudinal edges, each inflatable chamber having an inflation port adjacent one of the longitudinal edges, the inflation ports being defined by intermittent seals between the two sheets, and the two sheets having unsealed edge portions that extend beyond the inflation ports of the inflatable chambers, the apparatus comprising:

a web conveying system for conveying the inflatable web along a path of travel substantially parallel to the longitudinal edges of the inflatable web;

an inflation device comprising an inflation element arranged to intervene between the edge portions of the two sheets, the inflation element defining a gas outlet port through which gas is discharged into each inflation port in turn as the inflatable web is conveyed along the path of travel;

a sealing device for sealing the two sheets together to seal closed the inflation ports after inflation of the inflatable chambers by the inflation device; and

a web tracking system structured and arranged to continually adjust a transverse position of the inflatable web with respect to the inflation device so as to maintain said transverse position within a predetermined range; and

wherein the inflation element defines an internal passage extending therethrough that has an opening facing the intermittent seals of the inflatable web, and wherein the tracking system comprises a contact sensor element movably mounted in the internal passage and protruding out from the opening, the contact sensor element being arranged to be contacted by ends of the intermittent seals such that a position of the contact sensor element indicates the transverse position of the inflatable web.

14. The apparatus of claim 13 , further comprising a position sensor mounted proximate the contact sensor element and operable to detect the position of the contact sensor element.

15. The apparatus of claim 14 , wherein the position sensor comprises an optical sensor.