Apparatus and method for making inflated articles

1. An apparatus for making inflated containers from a film web having two juxtaposed film plies, comprising:

a. a first sealing device for producing a series of transverse seals that bond the film plies together;

b. an inflation assembly for directing gas between the film plies;

c. a second sealing device for producing one or more longitudinal seals that bond the film plies together, said transverse seals and said longitudinal seals intersecting to enclose the gas between the film plies to thereby form one or more inflated containers; and

d. at least one intermediate sealing element for producing one or more intermediate seals that bond the film plies together, said intermediate seals partitioning said containers into two or more compartments and providing at least one flow passageway between said compartments to allow said compartments to fluidly communicate with one another, wherein, said intermediate seals provide the inflated containers with hinge-like flexible regions.

2. The apparatus of claim 1 , wherein said first sealing device comprises

a transverse sealing element; and

said intermediate sealing element.

3. The apparatus of claim 2 , wherein

a. said apparatus further includes a mechanism that conveys the film web along a path of travel; and

b. said first sealing device comprises at least one rotary component, which is adapted to bring said transverse and intermediate sealing elements into rotational contact with the film web as the web is conveyed along said path of travel,

whereby, said first sealing device forms said transverse seals and intermediate seals as the film web is conveyed along said path of travel.

4. The apparatus of claim 1 , wherein said second sealing device comprises a longitudinal sealing element and at least one rotary component, said rotary component being adapted to bring said longitudinal sealing element into rotational contact with the film web to form said longitudinal seal as the web is conveyed along a path of travel.

5. The apparatus of claim 1 , wherein

said second sealing device produces a discontinuous series of longitudinal seals; and

said first and second sealing devices are synchronized such that each longitudinal seal intersects a pair of said transverse seals to enclose the gas between said film plies.

6. The apparatus of claim 1 , wherein said second sealing device comprises:

a. a rotatable support cylinder having an outer, circumferential surface; and

b. a heating element disposed about at least a portion of said outer surface of said cylinder and secured to said cylinder such that said heating element rotates with said cylinder, said heating element being coiled about the outer surface of said cylinder to form a helical pattern.

7. The apparatus of claim 6 , wherein said heating element forms an overlapping helical pattern.

8. A method for making inflated containers from a film web having two juxtaposed film plies, comprising:

a. producing a series of transverse seals that bond the film plies together;

b. directing gas between said film plies;

c. producing one or more longitudinal seals that bond the film plies together, said transverse seals and said longitudinal seals intersecting to enclose the gas between said film plies to thereby form one or more inflated containers; and

d. producing one or more intermediate seals that bond the film plies together, said intermediate seals partitioning said containers into two or more compartments and providing at least one flow passageway between said compartments to allow said compartments to fluidly communicate with one another, wherein, said intermediate seals provide the inflated containers with hinge-like flexible regions.

9. An apparatus for making inflated containers from a film web having two juxtaposed film plies, comprising:

a. an inflation assembly for directing gas between the film plies;

b. a sealing device for producing a series of transverse seals that bond the film plies together to enclose the gas between the film plies, thereby forming one or more inflated containers; and

c. at least one intermediate sealing element for producing one or more intermediate seals that bond the film plies together, said intermediate seals partitioning said containers into two or more compartments and providing at least one flow passageway between said compartments to allow said compartments to fluidly communicate with one another, wherein, said intermediate seals provide the inflated containers with hinge-like flexible regions.