Apparatus and method for making inflated articles

1. A sealing device, comprising:

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 and secured thereto such that said heating element rotates therewith, said heating element being coiled at least twice about said outer surface in the form of an overlapping double helical pattern,

whereby, juxtaposed film plies may be sealed together by bringing said device into rotational contact with the juxtaposed film plies and heating said heating element to a temperature sufficient to cause the film plies to seal together.

2. The device of claim 1 , further including a backing roller, wherein said rotatable support cylinder and said backing roller are structured and arranged to rotate against one another to create an area of tangential contact therebetween, which exerts a rotational compressive force on the film plies.

3. The device of claim 2 , further including a drive mechanism to power the rotation of at least one of said support cylinder and said backing roller.

4. The device of claim 1 , wherein

the film plies are bonded together with a series of transverse seals; and

said sealing device produces a discontinuous series of longitudinal seals that intersect said transverse seals.

5. 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; and

c. a second sealing device for producing a discontinuous series of longitudinal seals that bond the film plies together and intersect said transverse seals to enclose the gas between the film plies to thereby form inflated containers, said second sealing device comprising:

1) a rotatable support cylinder having an outer, circumferential surface, and

2) a heating element disposed about at least a portion of said outer surface and secured thereto such that said heating element rotates therewith, said heating element being coiled at least twice about said outer surface in the form of an overlapping double helical pattern,

whereby, said longitudinal seals are formed by bringing said second sealing device into rotational contact with the juxtaposed film plies and heating said heating element to a temperature sufficient to cause the film plies to seal together.

6. 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; and

c. producing a discontinuous series of longitudinal seals that bond the film plies together and intersect said transverse seals to enclose the gas between the film plies to thereby form inflated containers, wherein said longitudinal seals are formed by

1) bringing a sealing device into rotational contact with the juxtaposed film plies, said sealing device comprising a heating element coiled at least twice about at least a portion of an outer surface of a rotatable support cylinder in an overlapping double helical pattern and secured thereto such that said heating element rotates therewith, and

2) heating said heating element to a temperature sufficient to cause the film plies to seal together.

7. The apparatus of claim 5 , further including a backing roller, wherein said rotatable support cylinder and said backing roller are structured and arranged to rotate against one another to create an area of tangential contact therebetween, which exerts a rotational compressive force on the film plies.

8. The apparatus of claim 7 , further including a drive mechanism to power the rotation of at least one of said support cylinder and said backing roller.

9. The apparatus of claim 5 , wherein

the film plies are bonded together with a series of transverse seals; and

said sealing device produces a discontinuous series of longitudinal seals that intersect said transverse seals.

10. The method of claim 6 , wherein bringing the sealing device into rotational contact with the juxtaposed film plies includes rotating a backing roller against said rotatable support cylinder an area of tangential contact therebetween, which exerts a rotational compressive force on the juxtaposed film plies.

11. The method of claim 10 , further including powering, by a drive mechanism, rotation of at least one of said support cylinder and said backing roller.

12. The method of claim 6 , wherein

the film plies are bonded together with a series of transverse seals; and

said sealing device produces a discontinuous series of longitudinal seals that intersect said transverse seals.

13. The sealing device of claim 1 , wherein the support cylinder includes slots arranged to provide passageways for end portions of the heating element to traverse between an interior of the support cylinder and the outer surface of the support cylinder.

14. The sealing device of claim 13 , further comprising springs in the interior of the support cylinder, wherein the springs are arranged to secure the end portions of the heating element and to supply electrical current to the heating element.

15. The sealing device of claim 1 , wherein the outer surface includes a groove arranged to accommodate the heating element and to maintain the heating element in a position on the outer surface of the support cylinder.

16. The sealing device of claim 1 , wherein the film plies are sealed together by a series of transverse seals, and wherein the support cylinder is arranged such that the heating element is arranged to form discontinuous longitudinal seals in the film plies as the film plies are conveyed.

17. The sealing device of claim 16 , wherein the sealing device is arranged with respect to the film plies such that each of the discontinuous longitudinal seals intersects some of the transverse seals.

18. The sealing device of claim 17 , wherein the series of transverse seals form portions of inflatable containers, and wherein the sealing device is arranged such that each of the discontinuous longitudinal seals is capable of sealing closed at least one of the inflatable containers.

19. The sealing device of claim 18 , wherein the sealing device is further arranged such that each of the discontinuous longitudinal seals is capable of sealing closed two adjacent inflatable containers of the inflatable containers.

20. The sealing device of claim 16 , wherein the heating element disposed about the outer surface has a length based on an expected distance between transverse seals in the series of transverse seals.