Automated gusset inflation system and method

1. An apparatus for maintaining the inflation level of a bubble formed by nips in a moving roll of tubular film, said apparatus comprising:

a. a processor which receives input signals and transmits output signals;

b. at least one inflation sensor which senses the inflation level of the bubble and sends a signal to the processor;

c. at least one valve which receives a signal from the processor and opens, releasing pressurized air to a nozzle; and

d. at least one nozzle which is positioned and configured to release a burst of pressurized air such that the pressurized air pierces the film and injects air into the bubble to maintain or restore its inflation.

2. The apparatus of claim 1 wherein the valve is a solenoid valve.

3. The apparatus of claim 1 wherein the inflation sensor is an ultrasonic sensor.

4. The apparatus of claim 1 additionally comprising at least one photoelectric sensor.

5. The apparatus of claim 4 wherein the photoelectric sensor detects the position of the film based upon the film print and sends input signals to the processor.

6. The apparatus of claim 1 additionally comprising at least one encoder.

7. The apparatus of claim 6 wherein the encoder senses the number of revolutions of a film roller and transmits information to the processor.

8. The apparatus of claim 6 wherein the at least one encoder is an optical encoder.

9. The apparatus of claim 1 additionally comprising at least one gusseting mechanism which gussets the roll of tubular film.

10. The apparatus of claim 1 wherein the processor is a programmable logic controller.

11. The apparatus of claim 1 additionally comprising at least one human machine interface which receives input signals from and sends output signals to the processor.

12. The apparatus of claim 1 wherein the pressure utilized with the nozzle is from about 50 psi to about 150 psi.

13. The apparatus of claim 1 wherein the pressure utilized with the nozzle is from about 75 psi to about 125 psi.

14. The apparatus of claim 1 wherein the pressure utilized with the nozzle is from about 80 psi to about 100 psi.

15. The apparatus of claim 1 wherein the pressure utilized with the nozzle is about 90 psi.

16. The apparatus of claim 1 wherein the injection of pressurized air from the nozzle is from about 1 to about 50 milliseconds in duration.

17. The apparatus of claim 1 wherein the injection of pressurized air from the nozzle is from about 5 to about 20 milliseconds in duration.

18. The apparatus of claim 1 wherein the injection of pressurized air from the nozzle is about 10 milliseconds in duration.

19. The apparatus of claim 1 wherein the nozzle is stationary.

20. An apparatus for maintaining the inflation level of a bubble formed by nips in a moving roll of tubular film, said apparatus comprising:

a. a processor which receives input signals and transmits output signals;

b. at least one inflation sensor which senses the inflation level of the bubble and sends a signal to the processor;

c. at least one valve which receives a signal from the processor and opens, releasing pressurized air to a nozzle;

d.at least one nozzle which is positioned and configured to release a burst of pressurized air such that the pressurized air pierces the film and injects air into the bubble to maintain or restore its inflation; and

e. at least one photoelectric sensor which detects the position of the film based upon the film print and sends input signals to the processor.

21. An apparatus for maintaining the inflation level of a bubble formed by nips in a moving roll of tubular film, said apparatus comprising:

a. a processor which receives input signals and transmits output signals;

b. at least one inflation sensor which senses the inflation level of the bubble and sends a signal to the processor;

c. at least one valve which receives a signal from the processor and opens, releasing pressurized air to a nozzle;

d. at least one nozzle which is positioned and configured to release a burst of pressurized air such that the pressurized air pierces the film and injects air into the bubble to maintain or restore its inflation;

e. at least one photoelectric sensor which detects the position of the film based upon the film print and sends input signals to the processor; and

f. at least one encoder which senses the number of revolutions of a film roller and transmits information to the processor.

22. A method for maintaining the inflation level of a bubble formed by nips in a moving roll of tubular film without damaging a bag made from the film, the method comprising:

a. sensing the inflation level of the bubble;

b. sensing the position of the film relative to a pressurized air nozzle;

c. upon an indication of a low inflation level, injecting a burst of pressurized air into the film bubble such that the pressurized air pierces the film at a position in the film that will become the discarded handle cutout, thereby injecting air into the bubble; and

d. repeating the injection step until the inflation level of the bubble is sensed at an appropriate level.

23. The method of claim 22 , wherein the method is used to make a t-shirt type plastic grocery bag.

24. The method of claim 22 , wherein the method is used in a gusseting operation.

25. A method for maintaining the inflation level of a bubble formed by nips in a moving roll of tubular film, said method comprising manually activating a release of a burst of pressurized air from a stationary nozzle to inflate the tubular film, wherein the pressurized air released from the nozzle pierces the film and injects air into the tubular film to maintain or restore its inflation.

26. The method of claim 25 wherein the method further comprises at least one photoelectric sensor and at least one encoder, wherein the photoelectric sensor and the encoder operate to release the pressurized air to contact the tubular film at a predetermined location after the nozzle is manually activated, wherein the predetermined location is a portion of the film that will be discarded from an end product prepared from the film.