On-demand inflatable packaging

1. A method for converting a web of preformed plastic pouches to on-demand inflatable packaging, the plastic pouches being defined by side edges, two panels, and at least one panel having an inflation pattern, the inflation pattern of each of the plastic pouches is uninflated such that the web is in a non-inflated state, the web having a continuous inflation channel that is in fluid communication with the inflation pattern of each of the plastic pouches, the method comprising:

moving the web along a path of travel;

attaching a plastic outer skin to an outside of the web when the web is in the non-inflated state such that each of the preformed pouches of the web is configured to be inflated by inflating the inflation pattern of the preformed pouches with the plastic outer skin already attached to the outside of the web, wherein a first layer of the plastic outer skin is attached to a first panel of the two panels of the preformed pouches and a second layer of the plastic outer skin is attached to a second panel of the two panels of the preformed pouches, wherein the plastic outer skin is only attached to the web along edge lines of the preformed pouches and the plastic outer skin is detached from the web between the edge lines of the preformed pouches, and wherein the plastic outer skin is attached to the outside of the web such that the continuous inflation channel extends above the plastic outer skin;

packaging the web into a stored configuration when the web is in the non-inflated state and after the plastic outer skin is attached to the web.

2. The method of claim 1 further comprising:

moving the web along a second path of travel after the plastic outer skin is attached to the web;

inflating the inflation pattern of each of the preformed pouches such that each of the preformed pouches is in an inflated state;

sealing each of the preformed pouches in the inflated state to form a cushioning material.

3. The method of claim 2 further comprising:

closing each of the preformed pouches;

sealing the plastic outer skin in a closed position around each of the preformed pouches;

separating the web into a plurality of padded envelopes.

4. The method of claim 3 wherein the preformed pouches and the plastic outer skin are each closed at the same time.

5. The method of claim 1 further comprising:

moving the web along a second path of travel after plastic outer skin is attached to the web;

depositing at least one product into each of a plurality of the preformed pouches;

inflating the inflation pattern of each of the preformed pouches such that each of the preformed pouches is in an inflated state;

sealing each of the preformed pouches in the inflated state to form a cushioning material;

closing each of the preformed pouches;

sealing the outer skin in a closed position around each of the plurality of the preformed pouches;

separating the web into a plurality of padded envelopes, each of the plurality of the padded envelopes containing at least one product.

6. The method of claim 5 wherein the preformed pouches and the plastic outer skin are each closed at the same time.

7. The method of claim 1 wherein the two panels of each pouch are positioned to define an open end and a closed end.

8. The method of claim 1 further comprising:

at least partially inflating the inflation pattern of each of the preformed pouches; and

flattening each of the preformed pouches before packaging the web into the stored configuration such that the preformed pouches are in the non-inflated state when the web is in the stored configuration.