Web and method for making fluid filled units

1. A process of forming dunnage units from a preformed web, the process comprising:

providing the preformed web, wherein the preformed web includes a plurality of pouch defining seals between top and bottom layers that define a plurality of pouches, wherein the preformed web includes a pocket bounded by the top and bottom layers, an inflation edge of the web, and ends of the pouch defining seals, wherein the preformed web includes an inflation side line of perforations, a spaced apart opposite side line of perforations, and a gap forming area between the inflation side line of perforations and the opposite side line of perforations, wherein the inflation side line of perforations, the opposite side line of perforations, and the gap forming area extend in a direction that is transverse to the inflation edge of the web, the inflation side line of perforations extends between said inflation edge of said preformed web and said gap forming area, the opposite side line of perforations extends between an opposite edge of said preformed web and said gap forming area;

inserting a guide pin into the preformed pocket of the preformed web after the preformed web is formed;

inflating the pouches defined by the preformed web to an inflated volume that causes edges of the gap forming area to spread apart between the preformed inflation side line of perforations and the preformed spaced apart opposite side line of perforations;

forming an inflation seal across the preformed pouch defining seals to convert the inflated pouches to dunnage units, wherein a portion of the inflation side line of perforations is between the inflation edge and the inflation seal and a portion of the inflation side line of perforations is between the gap forming area and the inflation seal; and

substantially maintaining the inflated volume as the preformed pouches are sealed.

2. The process of claim 1 wherein said gap forming area comprises weak connections and wherein said weak connections break upon inflation to cause said edges of said gap forming area to spread apart.

3. The process of claim 1 further comprising engaging a leading dunnage unit between the inflation edge line of perforations and the opposite edge line of perforations and pulling the leading dunnage unit relatively away from an adjacent trailing dunnage unit to separate the leading dunnage unit from the trailing dunnage unit.

4. The process of claim 3 wherein the step of engaging a dunnage unit between the inflation side line of perforations and the opposite side line of perforations and pulling the dunnage unit relatively away from an adjacent dunnage unit to separate the adjacent dunnage units is performed by engaging a leading dunnage unit between the inflation side line of perforations and the opposite side line of perforations and pulling the leading dunnage unit relatively away from the adjacent trailing unit to separate the leading dunnage unit from the trailing dunnage unit.

5. A process of forming dunnage units from a preformed web, the process comprising:

providing the preformed web, wherein the preformed web includes a plurality of pouch defining seals between top and bottom layers that define a plurality of pouches, wherein the preformed web includes a pocket bounded by the top and bottom layers, an inflation edge of the web, and ends of the pouch defining seals, wherein the preformed web includes an inflation side line of perforations, a spaced apart opposite side line of perforations, and a gap forming area between the inflation side line of perforations and the opposite side line of perforations, wherein the inflation side line of perforations, the opposite side line of perforations, and the gap forming area extend in a direction that is transverse to the inflation edge of the web, the inflation side line of perforations extends between said inflation edge of said preformed web and said gap forming area, the opposite side line of perforations extends between an opposite edge of said preformed web and said gap forming area;

inserting a guide pin into the pocket of the preformed web after the web is formed;

feeding the web of side connected pouches along a path of travel to and through an inflation station;

sequentially inflating the pouches, wherein inflating the pouches causes edges of the gap forming area to spread apart and form a gap between a portion of the pouch being inflated and a portion of an adjacent pouch;

passing each inflated pouch to and through a sealing station that forms an inflation seal across the pouch defining seals to convert each inflated pouch into a dunnage unit; and

breaking open said preformed pocket of the web with a blunt surface after the guide pin is inserted into the pocket.

6. The process of claim 5 further comprising engaging a dunnage unit between the inflation side line of perforations and the opposite side line of perforations and pulling the dunnage unit relatively away from an adjacent dunnage unit to separate the adjacent dunnage units.

7. The process of claim 5 wherein said gap forming area comprises weak connections and wherein said weak connections break upon inflation to form said gap between said portion of said pouch being inflated and said portion of said adjacent pouch.

8. The process of claim 5 wherein opening said preformed pocket of the web comprises breaking a preformed line of perforations that extends along the inflation edge of the web.

9. A process of forming dunnage units from a preformed web, the process comprising:

providing the preformed web, wherein the preformed web includes a plurality of pouch defining seals between top and bottom layers that define a plurality of pouches, wherein the preformed web includes a pocket bounded by the top and bottom layers, an inflation edge of the web, and ends of the pouch defining seals, wherein the preformed web includes an inflation side line of perforations, a spaced apart opposite side line of perforations, and a gap forming area between the inflation side line of perforations and the opposite side line of perforations, wherein the inflation side line of perforations, the opposite side line of perforations, and the gap forming area extend in a direction that is transverse to the inflation edge of the web, the inflation side line of perforations extends between said inflation edge of said preformed web and said gap forming area, the opposite side line of perforations extends between an opposite edge of said preformed web and said gap forming area;

inserting a guide pin into the preformed pocket of the web after the preformed web is formed;

inflating the pouches defined by the preformed web to an inflated volume that causes edges of the gap forming area to spread apart between the preformed inflation side line of perforations and the preformed spaced apart opposite side line of perforations;

forming an inflation seal across the pouch defining seals to convert the inflated pouches to dunnage units, wherein a portion of the inflation side line of perforations is between the inflation edge and the inflation seal and a portion of the inflation side line of perforations is between the gap forming area and the inflation seal; and

breaking open perforations of said pocket with a blunt surface to open said pocket of the web, after the guide pin is inserted into the pocket.

10. The process of claim 9 wherein said gap forming area comprises weak connections and wherein said weak connections break upon inflation to cause said edges of the gap forming area to spread apart.

11. The process of claim 9 wherein said breaking open said pocket of the web comprises breaking a preformed perforation of the pocket of the web.

12. The process of claim 9 wherein said breaking open said pocket of the web comprises breaking a preformed inflation edge perforation of the pocket of the web.

13. A process of forming dunnage units from a preformed web, the process comprising:

providing the preformed web, wherein the preformed web includes a plurality of pouch defining seals between top and bottom layers that define a plurality of pouches, wherein the preformed web includes a pocket bounded by the top and bottom layers, an inflation edge of the web, and ends of the pouch defining seals, wherein the preformed web includes an inflation side line of perforations, a spaced apart opposite side line of perforations, and a gap forming area between the inflation side line of perforations and the opposite side line of perforations, wherein the inflation side line of perforations, the opposite side line of perforations, and the gap forming area extend in a direction that is transverse to the inflation edge of the web, the inflation side line of perforations extends between said inflation edge of said preformed web and said gap forming area, the opposite side line of perforations extends between an opposite edge of said preformed web and said gap forming area;

inserting a guide pin into the preformed pocket of the preformed web after the preformed web is formed;

inflating the pouches defined by the preformed web to an inflated volume that causes edges of a gap forming area to spread apart between the preformed inflation side line of perforations and the preformed spaced apart opposite side line of perforations;

forming an inflation seal across the preformed pouch defining seals to convert the inflated pouches to dunnage units, wherein a portion of the inflation side line of perforations is between the inflation edge and the inflation seal and a portion of the inflation side line of perforations is between the gap forming area and the inflation seal; and

breaking open said preformed pocket of the web with a blunt surface.

14. The process of claim 13 wherein the gap forming area comprises weak connections and wherein said weak connections break upon inflation to cause said edges of the gap forming area to spread apart.

15. The process of claim 13 wherein opening said pocket of the web comprises breaking preformed perforations of the pocket of the web with said blunt surface.