WO2018226561A1 - Article gonflable à fermeture hermétique automatique présentant une rétention de fluide améliorée sous charge - Google Patents

Article gonflable à fermeture hermétique automatique présentant une rétention de fluide améliorée sous charge Download PDF

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Publication number
WO2018226561A1
WO2018226561A1 PCT/US2018/035809 US2018035809W WO2018226561A1 WO 2018226561 A1 WO2018226561 A1 WO 2018226561A1 US 2018035809 W US2018035809 W US 2018035809W WO 2018226561 A1 WO2018226561 A1 WO 2018226561A1
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WO
WIPO (PCT)
Prior art keywords
film
self
inflatable article
film portion
sealing
Prior art date
Application number
PCT/US2018/035809
Other languages
English (en)
Inventor
Meghan FLANAGAN
Corbin NICHOLS
Janet Rivett
Original Assignee
Sealed Air Corporation (Us)
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sealed Air Corporation (Us) filed Critical Sealed Air Corporation (Us)
Publication of WO2018226561A1 publication Critical patent/WO2018226561A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D31/00—Bags or like containers made of paper and having structural provision for thickness of contents
    • B65D31/02—Bags or like containers made of paper and having structural provision for thickness of contents with laminated walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D31/00—Bags or like containers made of paper and having structural provision for thickness of contents
    • B65D31/14—Valve bags, i.e. with valves for filling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D33/00—Details of, or accessories for, sacks or bags
    • B65D33/005—Anti-slip or anti-skid bags, e.g. bags provided with anti-slip coating, ribs, strips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/051—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using pillow-like elements filled with cushioning material, e.g. elastic foam, fabric
    • B65D81/052—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using pillow-like elements filled with cushioning material, e.g. elastic foam, fabric filled with fluid, e.g. inflatable elements

Definitions

  • the present invention generally relates to a self-sealing inflatable article, and in particular to an article providing cushioning and/or dunnage and/or void fill for use in packaging.
  • the self-sealing inflatable article has an inflation channel which is maintained in a collapsed configuration by the internal pressure inside the article, which internal pressure is generated only upon inflation of the article.
  • Inflatable articles are commonly used as cushions to package items, either by wrapping the items in the inflatable articles and placing the wrapped items in a shipping carton, or by simply placing one or more inflatable articles inside a shipping carton along with an item to be shipped.
  • the inflated article(s) provide a cushioning function to protect the packaged item by absorbing impacts that might otherwise be transmitted to the packaged item during storage and shipment, and to provide dunnage and void fill functions in restricting the movement of the packaged item within the carton to further reduce the likelihood of damage during storage and shipment.
  • Inflatable packaging has an advantage over non-inflatable packaging in that inflatable packaging requires less raw material. Inflate-on-demand packaging allows the end user to inflate the packaging materials just prior to when needed.
  • Inflate-on-demand packaging materials occupy less space during shipment to the end user and less space in storage at the end user, relative to pre-inflated packaging articles. Due to the great difference in density between an inflated article (low density) and an uninflated inflatable article (high density), it is much more expensive to ship inflated cushioning articles from a manufacturer to an end user than to ship uninflated inflatable articles from the manufacturer to the end user.
  • a self-sealing inflatable article having a self-sealing valve which is maintained in a closed configuration whenever the pressure inside the inflated article exceeds ambient pressure it has been discovered that the inflatable article may have less than a desired level of fluid retention while under load over an extended period of time. More particularly, an inflated self-sealing inflatable article under a load of 3 pounds has been discovered to undergo an average fluid loss of about 15% @72 hours. Accordingly, a need exists in the art for a self-sealing inflatable packaging article which exhibits improved fluid retention under load.
  • a first aspect is directed to a self-sealing inflatable article, comprising a flexible film, an inflatable chamber, and a self-sealing one-way valve.
  • the flexible film includes a first film portion extending from a first transverse film edge to a first outer fold, a second film portion extending from the first outer fold to an inner fold, a third film portion extending from the inner fold to a second outer fold, and a fourth film portion extending from the second outer fold to a second transverse film edge.
  • the inflatable chamber is bounded by a first chamber side and a second chamber side.
  • the inflatable chamber is formed by perimeter seals of the first chamber side to the second chamber side.
  • the first chamber side includes at least the first film portion.
  • the second chamber side includes at least the fourth film portion.
  • the self-sealing one-way valve comprises an external valve opening, a collapsible self- sealing inflation channel, and at least one internal valve passageway from the inflation channel into the inflatable chamber.
  • the external valve opening is between the second film portion and the third film portion.
  • the self-sealing filling channel is between the second film portion and the third film portion, and extends transversely across the inflatable article from the external valve opening to the internal valve passageway and extends longitudinally between the first outer fold and the inner fold.
  • the internal valve passageway is through at least one member selected from the second film portion and the third film portion.
  • the film has an outside layer comprising a particulate antiblock component in an amount of at least
  • the particulate antiblock component has an average particle size of from 2 to 9 microns.
  • the particulate antiblock having a particle size distribution span of ⁇ 3.0.
  • the outside layer comprises the antiblock component in an amount of 0.5 to 5 wt %, based on layer weight, the particulate antiblock having an average particle size of from 2.5 to 8 microns, the particulate antiblock having a particle size distribution span of ⁇ 2.5.
  • the outside layer comprises the antiblock component in an amount of 0.5 to 3.0 wt %, based on layer weight.
  • the outside layer comprises the antiblock component in an amount of 0.7 to 2.5 wt %, based on layer weight, and the particulate antiblock has an average particle size of from 3 to 7 microns, and the particulate antiblock has a particle size distribution span of ⁇ 2.5.
  • the outside layer comprises the antiblock component in an amount of 1 to 2 wt %, based on layer weight.
  • the outside layer comprises the antiblock component in an amount of 1 .2 to 1 .8 wt %, based on layer weight, and the particulate antiblock has an average particle size of from 4 to 6 microns, and the particulate antiblock has a particle size distribution span of from 0.2 to 2.0. In a further embodiment, the particulate antiblock has a particle size distribution span of from
  • the particulate antiblock has a particle size distribution span of from 0.2 to 0.8.
  • the film comprises ethylene-based polymer in an amount of at least 95 wt %, based on total film weight, and at least 40 wt % of the ethylene-based polymer has a density ⁇ 0.925 g/cm 3 .
  • the film comprises ethylene-based polymer in an amount of at least 95 wt %, based on total film weight, at least 50 wt % of the ethylene-based polymer has a density ⁇ 0.925 g/cm 3 .
  • the film comprises ethylene-based polymer in an amount of at least 95 wt %, based on total film weight, at least 70 wt % of the ethylene-based polymer has a density ⁇ 0.925 g/cm 3 .
  • the particulate antiblock comprises at least one member selected from the group consisting of natural silica, synthetic silica, silicate, diatomaceous earth, fumed synthetic silica, precipitated synthetic silica, gelled synthetic silica, sodium calcium silicate, and sodium calcium aluminum silicate, talc, kaolin , clay, mica, silicate, aluminum silicate, silicon dioxide, ceramic spheres, alkali-alum ino-silicate ceramic spheres, magnesium silicate, calcium silicate, calcium carbonate, and magnesium oxide.
  • the particulate antiblock comprises at least one member selected from the group consisting of sodium calcium alumino-silicate and alkali-alumino-silicate ceramic spheres.
  • the outside film layer further comprises at least one slip agent selected from the group consisting of stearamide, bis-stearamide, ethylene bis-stearamide, stearyl stearamide, stearyl erucamide, erucyl erucamide, behanamide, lauramide, lauric diethanolamide, oieamide, ethylene bis-oieamide, oleyl palmitamide, monoglyceride, diglyceride, glycerol monoleate, glycerol monostearate, stearate ester, sorbitan stearate, mono stearate, di-stearate, tri- stearate, sorbitan monoiaurate, pentaerythritol stearate ester, polygiycerol stearate, zinc stearate, calcium stearate, magnesium stearate, sodium stearate, and potassium stearate.
  • slip agent selected from the group consisting of stearamide, bis-ste
  • the at least one slip agent is present in the film at a level of at least 500 parts per million, based on total film weight.
  • the antiblock particulates are present in the outside layer of the second film portion and the outside layer of the third film portion. [0021] In an embodiment, the antiblock particulates are present in the outside layer of the first film portion, the second film portion, the third film portion, and the fourth film portion.
  • the first chamber side comprises the first film portion and a section of the third film portion and the second film portion is heat sealed to the third film portion and the first film portion at a second transverse heat seal extending along a portion of the first outer fold.
  • the second film portion is heat sealed to the third film portion at a first transverse heat seal along at least a portion of the inner fold, and the second film portion is heat sealed to the third film portion and the first film portion at a second transverse heat seal along a portion of the first outer fold.
  • the first, second, third, and fourth film portions are formed of a single piece of film which is folded and creased at each of the first outer fold, the inner fold, and the second outer fold, and the antiblock particulates are present throughout the outside layer of the single piece of film.
  • the second film portion is heat sealed to the third film portion between the inner fold and the collapsible self-sealing inflation channel.
  • the second film portion is heat sealed to the third film portion between the first outer fold and the collapsible self-sealing inflation channel.
  • the inflatable article comprises two discrete pieces of film sealed to one another at a location selected from the group consisting of the first outer fold, the inner fold, and the second outer fold.
  • the inflatable article comprises three discrete pieces of film sealed to each other at two locations selected from the group consisting of the first outer fold, the inner fold, and the second outer fold.
  • the inflatable article comprises four discrete pieces of film sealed to each other, including a first seal, at the first outer fold, a second seal at the second outer fold, and a third seal at the third outer fold.
  • FIG. 1 is a perspective view of an embodiment of an inflatable article with integral valve in various states of completion wherein the internal valve opening comprises a round hole and the locator aperture is rectangular with rounded corners.
  • FIG. 2 is a perspective view of an embodiment of an inflatable article with integral valve in various states of completion wherein the internal valve opening comprises a notch and the locator aperture comprises a slit.
  • FIG. 3 is a perspective view of an embodiment of an inflatable article with integral valve in various states of completion wherein internal valve openings comprise notches and a slit and wherein the locator aperture comprises a slit.
  • FIG. 4 is a perspective view of an embodiment of an inflatable article with integral valve in various states of completion wherein the internal valve opening comprises a cut-off portion and wherein the seals run substantially perpendicular to the inner fold.
  • FIG. 5 is a perspective view of an embodiment of an inflatable article with integral valve in various states of completion wherein the internal valve opening comprises a cut-off portion and wherein the seals run both substantially
  • FIG. 6 is a perspective view of an embodiment of an inflatable article with integral valve in various states of completion wherein there are multiple enclosed chambers in each inflatable article.
  • FIG. 7 is a top view of an embodiment of a completed inflatable article with integral valve wherein the seal is rounded and the locator aperture comprises a slit.
  • FIG. 8 is a cutaway view showing the inner portions of an embodiment of an inflatable article and the air flow that occurs through the inflatable article during inflation wherein the internal valve opening comprises a round hole.
  • FIG. 9 is a perspective view of an embodiment of an inflatable article inline manufacturing process.
  • FIG. 10 is a perspective view of an embodiment of an inflatable article inflation device with mechanical registration device for use with a roll of inflatable articles.
  • FIG. 1 1 is a perspective view of an embodiment of a wall-mounted roll- based inflatable article inflation device in operation.
  • FIG. 12 is a perspective view of an embodiment of a table-mounted roll- based inflatable article inflation device in operation
  • FIG. 13 is a perspective view of an embodiment of a wall-mounted roll- based inflatable article inflation device in operation wherein the source of pressurized air is distant from the outlet.
  • FIG. 14 is a perspective view of an embodiment of a cartridge-based inflatable article inflation device in operation wherein the holder comprises a clamp.
  • FIG. 15 is a perspective view of an embodiment of a cartridge-based inflatable article inflation device in operation wherein the holder comprises pins.
  • FIG. 16 is a perspective view of an embodiment of a fold-based inflatable article inflation device in operation.
  • FIG. 1 illustrates a plurality of inflatable articles 10 in which a single piece of flexible film 11 has been punched, folded, sealed, and perforated to form a strand of the inflatable articles 10.
  • the strand of inflatable articles 10 may be formed advantageously from a unitary piece of flexible film 11 in an inline process, the strand of inflatable articles 10 may alternatively be formed from multiple pieces of flexible film.
  • flexible film refers to a material that can be changed into a large variety of determinate and indeterminate conformations without damage thereto in response to the action of an applied force, and can be returned to its general original conformation if desired.
  • Flexible films 11 of a thickness of 1 or 2 mils can be used, although films of other thicknesses could alternatively be used.
  • the film, including flexible film 11 may include one or more
  • thermoplastic materials e.g., polyethylene homopolymer or copolymer
  • thermoplastic polymers include polyethylene homopolymers, such as low density polyethylene (LDPE) and high density polyethylene (HDPE), and polyethylene copolymers such as heterogeneous (Zeigler-Natta catalyzed) ethylene/alpha-olefin copolymers, and homogeneous (metallocene, single-cite catalyzed)
  • LDPE low density polyethylene
  • HDPE high density polyethylene
  • polyethylene copolymers such as heterogeneous (Zeigler-Natta catalyzed) ethylene/alpha-olefin copolymers, and homogeneous (metallocene, single-cite catalyzed)
  • Ethylene/alpha-olefin copolymers are copolymers of ethylene with one or more comonomers selected from C3 to C20 alpha-olefins, such as 1 -butene, 1 -pentene, 1 -hexene, 1 -octene, methyl pentene and the like, in which the polymer molecules comprise long chains with relatively few side chain branches, including linear low density polyethylene (LLDPE), linear medium density polyethylene (LMDPE), very low density polyethylene (VLDPE), and ultra-low density polyethylene (ULDPE).
  • LLDPE linear low density polyethylene
  • LMDPE linear medium density polyethylene
  • VLDPE very low density polyethylene
  • ULDPE ultra-low density polyethylene
  • Various other materials are also suitable such as, e.g., polypropylene homopolymer or polypropylene copolymer
  • polyesters e.g., propylene/ethylene copolymer
  • polystyrenes e.g., polystyrenes
  • polyamides e.g., polycarbonates
  • polyvinyldene chloride saponified ethylene vinyl acetate (i.e., EVOH), polyvinyl alcohol (i.e., PVOH), etc.
  • ethylene/unsaturated ester copolymer such as ethylene/vinyl acetate copolymer, ethylene/methyl acrylate copolymer, and ethylene/unsaturated acid copolymers, etc., and ionomer resin.
  • the film may be a monolayer film or a multilayer film. If a monolayer film, the single layer may contain one or more of the polymers in the paragraph above. If a multilayer film, one or more layers, or all the layers, may contain one or more of the polymers in the paragraph above.
  • the film is a multilayer film, it is advantageous for production and use to provide a relatively simple symmetrical film structure, such as the 3-layer film structures of various examples disclosed herein. Providing the same polymeric composition (and optionally also providing the same type and amount of additives) to both outer film layers simplifies production and can allow the film to be used with either outer layer as the inside layer or the outside layer of the inflatable article.
  • the outer film layers may be symmetrical with respect to composition, or thickness, or both, it may also be advantageous to make the outer layers asymmetrical in composition and/or thickness.
  • a thicker outside layer may provide more abuse-resistance.
  • a thicker seal layer may provide enhanced seal strength and greater abuse resistance.
  • the inner layer or layers may contain a polymer which is stiffer and of higher density (e.g., medium density polyethylene, i.e., MDPE) than the polymers in the outer layer, to improve the machinability of the film.
  • MDPE medium density polyethylene
  • a self-sealing inflatable article made from a multilayer film opposite the outside layer of the film is the other outer layer of the film, i.e., the layer which serves as the inside layer of the inflatable article.
  • the inside layer is the primary seal layer of the film, although small areas of the outside layer of the film are also sealed together at the ends of the valve passageway.
  • the inside layer of the film may be made from a polymer composition which is readily heat sealable by conventional heat sealing means such as hot bar sealing, impulse sealing, ultrasonic sealing, etc.
  • Polymers which are recognized as being readily heat sealable include polyethylenes, particularly ethylene/alpha-olefin copolymers having a density of from 0.88 to 0.92 g/cc, including linear low density
  • Flexible film 11 may be made by any known coextrusion process by melting the component polymer(s) and extruding or coextruding them through one or more flat or annular dies.
  • Composite, e.g., multilayered, materials may be employed to provide a variety of additional characteristics such as durability, enhanced gas-barrier functionality, enhanced heat sealability, etc.
  • the phrase "outside layer” refers to all film surfaces which are opposite to the film surface in direct contact with the interior of the inflatable chamber.
  • the first and fourth film portions each have an outside layer which forms a portion of the outside surface of the inflatable article.
  • the second and third film portions each have outside layers opposite their surfaces in direct contact with the interior of the inflatable chamber, with at least a portion of the outside surfaces of the second and third film portions being in direct contact with the internal valve passageway from the inflation channel to the inflatable chamber.
  • the phrase "inside layer” refers to the layer of the film which has a surface which provides the inside surface of the inflatable article, and is in direct contact with the interior of the inflatable chamber.
  • the second and third film portions each have an inside layer at least a section of which is in contact with the interior of the inflatable chamber; each also have an outside layer at least a section of which is a film surface forms the film surfaces outside of the inflatable chamber but inside and in direct contact with the internal valve passageway from the inflation channel to the inflatable chamber.
  • the term "fold” is used generically in the description of the inflatable article, to encompass a single piece of film which doubles back upon itself, or two pieces of film with the second piece doubling back upon the first piece. That is, a single piece of film may be configured to double back upon itself at the fold; the fold may be uncreased or creased, and if uncreased, is capable of being creased by being pressed flat. In the embodiment in which the fold is a doubling back of a single piece of film upon itself, the fold is of the type which has a crease or can be provided with a crease if pressed flat while the inflatable article is uninflated.
  • Two pieces of film can be configured so that a second piece of film doubles back on a first piece of film at a fold formed by a seal of the first piece of film to the second piece of film.
  • the first piece of film may be sealed to the second piece of film at the fold, i.e., the point at which the second piece of film doubles back on the first piece of film.
  • the fold is not required to be at the position of the seal, but typically is at the position of the seal due to the manner in which the inflatable article can be produced.
  • the phrase "inner fold” refers to any fold which is positioned inside the confines of the inflatable chamber.
  • the term "chamber” refers to the volume inside the self- sealing inflatable article once the article has sealed itself closed.
  • the chamber is defined by the film portions which are under tension when the inflatable article is inflated and self-sealed.
  • the chamber sides are defined by those portions of the film that are under tension upon inflation of the inflatable article, which portions are on opposing sides of the inflatable article.
  • the film may be a monolayer film or a multilayer film.
  • the film may have a number of layers corresponding with 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, or more.
  • the film is a 3-layer film having two outer layers and a core layer between the outer layers.
  • one of the outer layers is the outside layer of the inflatable article.
  • the other outer layer is the inside layer of the inflatable article.
  • the core layer is an inner layer, i.e., an interior layer of the film.
  • the film may have a symmetrical construction in terms of layer composition and/or layer thickness.
  • the film may have an A/B/A structure, in which the A layers have the same composition and/or the same layer thickness.
  • a film with an A/B/A structure in which the A layers have the same composition can provide a high degree of balance of properties; can be simpler to manufacture than, for example, an A/B/C structure; can be simpler to convert to the inflatable article because the symmetrical structure allows the film to be used with either A layer as the inside layer of the inflatable article.
  • films with symmetrical layer arrangement regarding layer composition may exhibit superior air retention compared with films of asymmetrical layer arrangement. See comparison of Film No. 1 with Film No. 6, below.
  • the outside layer of the film is provided with an antiblock agent (a particulate solid material with particles that enhance the surface roughness of the film) so that the article is readily inflatable in the manner disclosed herein, i.e., so that the film surfaces in the collapsible one-way self-sealing valve do not adhere to one another to a degree preventing the ready inflatability of the article in the manner described herein (upon the folding of the film to make the inflatable article, the one-way valve has internal surfaces corresponding with the outside surface of the inflatable article).
  • an antiblock agent a particulate solid material with particles that enhance the surface roughness of the film
  • the antiblock particles are present in the outside layer at a size, and at a loading level, which balances (i) ensuring that the valve opens so that the article is readily inflatable in the manner disclosed herein, and (ii) ensuring that upon full inflation the valve closes so that the inflation gas is substantially retained in the inflatable article, i.e., to a degree that undesired levels of gas leakage back through the valve does not occur. If the antiblock particles are too large and/or the antiblock particulate loading level is too high, an undesired level of gas leakage from the inflated article may occur. If the antiblock particles are too small and/or the antiblock particulate loading level is too low, an undesired level of film blocking (i.e. , film surfaces sticking together) may prevent the inflatable article from exhibiting the ready inflatability in the manner disclosed herein.
  • the outside layer may contain antiblock particulates in an amount of 0.5 wt % to 5 wt %, based on layer weight; or 0.5 to 3 wt %, or 0.5 to 2.5 wt %, or 0.5 to 2 wt %, or 0.5 to 1 .5 wt %, or 0.5 to 1 .4 wt %, or 0.6 to 1 .3 wt %, or 0.7 to 2.5 wt %, or 0.7 to 2 wt %,or 0.7 to 1 .5 wt %, or 0.7 to 1 .2 wt %, or 1 to 2 wt %, or 0.8 to 1 .1 wt %, or 0.9 to 1 .0 wt %, based on layer weight.
  • the antiblock particulates in the outside layer may have an average particle size of 2 ⁇ to 9 ⁇ ; or 2 ⁇ to 8 ⁇ ; 2.5 ⁇ to 8 ⁇ ; or 3 ⁇ to 9 ⁇ ; or 3 ⁇ to 8 ⁇ ; or 3 ⁇ to
  • Antiblock particulate particle size distribution can be expressed in terms of "Particle Size Distribution Span," i.e., PSDS.
  • PSDS particle Size Distribution Span
  • the Particle Size Distribution Span is calculated by (A) subtracting (i) the particle size at which 10 wt% of the particles are smaller, from (ii) the particle size at which 90 wt % of the particles are smaller, to obtain (iii) a particle size difference representing the particle size range of the central 80 wt % of the particles, and thereafter dividing (iii) by the particle size at which 50 wt % of the particles are smaller.
  • Particle Size Distribution Span is calculated by (A) subtracting (i) the particle size at which 10 wt% of the particles are smaller, from (ii) the particle size at which 90 wt % of the particles are smaller, to obtain (iii) a particle size difference representing the particle size range of the central 80 wt % of the particles, and thereafter dividing (iii) by the particle
  • Particle Size Distribution Span (D ⁇ go% - D ⁇ i o%) / D ⁇ so%, where D ⁇ go% represents the size at which 90 wt % of the particles are smaller, D ⁇ i o% represents the size at which 10 wt % of the particles are smaller, and D ⁇ so%
  • PSDS represents the size at which 50 wt % of the particles are smaller.
  • a relatively small PSDS corresponds with a relatively narrow bell curve of particle size distribution.
  • a relatively large PSDS corresponds with a relatively broad bell curve of particle size distribution.
  • D ⁇ 9o% and D ⁇ i o% indicates the degree of symmetry of the bell curve. That is, if
  • D ⁇ 5o% is midway between D ⁇ go% and D ⁇ i o%
  • the bell curve is relatively symmetrical.
  • the further D ⁇ so% is from being midway between D ⁇ go% and D ⁇ i o%, the more asymmetrical the bell curve is. If D ⁇ so% is closer to D ⁇ go% than to D ⁇ i o%, there is a relative "tailing off" of the bell curve on the low end of the particle size, versus the shape of the bell curve on the upper end of the particle size. This is a measure of symmetry of size distribution.
  • PSDS is a unitless number.
  • the PSDS of the antiblock particulates can be or ⁇ 5, or ⁇ 4, or ⁇ 3, or ⁇ 2.5, or ⁇ 2.4, or ⁇ 2.3, or ⁇ 2.2, or ⁇ 2.1 , or ⁇ 2.0, or ⁇ 1 .9, or ⁇ 1 .8, or ⁇ 1 .7, or ⁇ 1 .6, or ⁇ 1 .5, or ⁇ 1 .4, or ⁇ 1 .3, or ⁇ 1 .2, or ⁇ 1 .1 , or ⁇ 1 .0, or ⁇ 0.9, or ⁇ 0.8, or ⁇
  • ⁇ 0.6 or from 0.2 to 3, or from 0.3 to 2.5, or from 0.4 to 2.0, or from 0.4 to 1 .5, or from 0.4 to 1 .0, or from 0.4 to 0.8, or from 0.4 to 0.6, or from 0.4 to 0.5.
  • At least 30 wt % of the antiblock particles have a size of from 4 ⁇ to 6 ⁇ ; or 40 wt %, or 50 wt %, or 60 wt %, or 70 wt %, or 80 wt % of the particles have a size of from 4 ⁇ to 6 ⁇ .
  • ⁇ 5 wt % of the particles have a size > 40 ⁇ , or ⁇ 5 wt % are > 35 ⁇ , or ⁇ 5 wt % are > 30 ⁇ , or ⁇ 5 wt % are >25 ⁇ , or ⁇ 5 wt % are > 20 ⁇ , or ⁇ 5 wt % are > 17 ⁇ , or ⁇ 5 wt % are > 15 ⁇ , or ⁇ 5 wt % are > 12 ⁇ .
  • Measurement of particle size and particle size distribution can be carried out using scanning electron microscopy, using nominal magnifications of 1000X and 5000X.
  • a sample of the particulate material is taken from a bottle with a spatula and deposited on conductive carbon tape, then imaged at five arbitrary sites with the scanning electron microscope.
  • every particle on which the diameter is visible is measured via calibrated software, and a particle size distribution is calculated based on the combined results.
  • the outside layer may have any desired thickness, or may have a thickness of from 0.1 mil to 1 mil, or from 0.2 mil to 0.8 mil, or from 0.25 to 0.6 mil, from 0.3 mil to 0.5 mil, or from 0.3 mil to 0.4 mil, or from 0.32 mil to 0.38 mil.
  • the outside layer of the film is the other outer layer of the film, i.e., the layer which serves as the inside layer of the inflatable article.
  • the inside layer is the primary seal layer of the film, although small areas of the outside layer of the film are also sealed together at the ends of the valve passageway.
  • the inside layer of the film may be made from a polymer composition which is readily heat sealable by conventional heat sealing means such as hot bar sealing, impulse sealing, ultrasonic sealing, etc.
  • Polymers which are recognized as being readily heat sealable include polyethylenes, particularly ethylene/alpha-olefin copolymers having a density of from 0.88 to 0.92 g/cc, including linear low density
  • polyethylene very low density polyethylene and ultra low density polyethylene, homogeneous ethylene/alpha-olefin copolymer, ethylene/alpha-olefin plastomer, ionomer resin, ethylene/unsaturated ester copolymer such as ethylene/vinyl acetate copolymer, propylene/ethylene copolymer, etc., as known to those of skill in the art.
  • the inside layer may have any desired thickness.
  • the inside layer should have a thickness great enough that it, either alone or in combination with one or more adjacent film layers, alone, produces a heat seal of adequate strength to withstand the use to which the inflatable article is put.
  • the heat seal layer may have a thickness of from 0.1 mil to 1 mil, or from 0.15 mil to 0.8 mil, or from 0.2 to
  • the multilayer film may have a core layer which provides the film with any desired property, such as strength, gas barrier, flexibility, energy absorption, clarity or opacity, etc. It has been found that the valve in the self-sealing inflatable article exhibits less gas leakage after inflation if the film is relatively flexible. More particularly, it has been discovered that an A/B/A film having a B layer made from linear low density polyethylene with a density of 0.92 g/cm 3 retains more air than an otherwise similar film having a core layer made from medium density polyethylene having a density of 0.931 g/cm 3 .
  • the core layer may have a thickness of from 0.1 mil to 1 mil, or from 0.2 to 0.9 mil, or from 0.25 mil to 0.8 mil, or from 0.3 mil to 0.75 mil, or from 0.35 mil to
  • the term "film” is inclusive of plastic web, regardless of whether it is film or sheet.
  • the total film thickness can be any desired thickness.
  • the total film thickness can be from 0.2 to 10 mils, or 0.3 mil to 3 mils, or from 0.4 to 2.5 mils, or from 0.5 to 2 mils, or from 0.6 to 1 .8 mils, or from 0.7 to
  • the polymeric component(s) in the film can be made primarily, or entirely, from ethylene-based polymer.
  • the ethylene-based polymer can be present in the film in an amount of at least 95 wt %, based on total film weight, with at least 40 wt % of the ethylene-based polymer having a density ⁇ 0.925 g/cm 3 .
  • the ethylene-based polymer is present in the film in an amount of at least 95 wt %, based on total film weight, and at least 50 wt %, or at least 60 wt %, or at least 70 wt %, or at least 80 wt %, or at least 90 wt %, of the ethylene-based polymer has a density ⁇ 0.925 g/cm 3 .
  • the slip agent may include at least one member selected from the group consisting of stearamide, bis-stearamide, ethylene bis-stearamide, steary! stearamide, stearyl erucamide, erucyl erucamide, behanamide, lauramide, lauric diethanolamide, oieamide, ethylene bis-oieamide, oleyl pa!mitamide, monoglyceride, diglyceride, glycerol monoleate, glycerol monostearate, stearate ester, sorbitan stearate, mono stearate, di-stearate, tri-stearate, sorbitan mono!aurate, pentaerythritol stearate ester, polyglycerol stearate, zinc stearate, calcium stearate, magnesium stearate, sodium stearate, and potassium stearate. Slip agents added
  • the slip agent may be present in the film at a level of at least 100 ppm, on a total film weight basis, or at a level of from 100 ppm to 10,000 ppm on a total film weight basis, or from 300 ppm to 8000 ppm, or from 400 ppm to 6000 ppm, or from 500 ppm to 4000 ppm, or from 600 ppm to 2500 ppm, or from 700 ppm to 2000 ppm, or from 800 ppm to 1900 ppm, or from 900 ppm to 1800 ppm, or from 900 ppm to 1410 ppm, or from 1000 ppm to 1700 ppm, or from 1 100 ppm to 1610 ppm, or from 1200 ppm to 1500 ppm, or from 1300 ppm to 1450 ppm, or from 1350 ppm to 1410 ppm, on a total film weight basis.
  • the inflatable article is herein deemed to have a "length" corresponding with the distance from the article edge closest to the valve (e.g., the second outer fold) to the opposite edge of the article.
  • a “longitudinal” direction e.g., the side seals 15L illustrated in various figures disclosed herein.
  • peripheral seal refers to any seal which defines an outer boundary of the inflatable chamber with the inflatable article in its lay-flat configuration, i.e., uninflated. Perimeter seals include the longitudinal side seals and the transverse bottom seal. The transverse heat seals along each side of the inflation channel are not included as perimeter seals.
  • the inflatable article is herein deemed to have a "width" corresponding with the distance across the inflatable article from one sealed side-edge to the opposite sealed side-edge.
  • Features running in a "transverse” direction e.g., the bottom seal 15T illustrated in various figures disclosed herein are features running across the width of the inflatable article.
  • article 10 generally comprises flexible film 11 defining enclosed chamber 13 and one-way valve 14 defined at least in part by flexible film 11.
  • one-way valve 14 is meant to describe a valve that allows fluid flow in one direction (i.e., into the chamber), but substantially impedes fluid flow in the opposite direction (i.e., out of the chamber).
  • one-way valve 14 may allow for flow in both directions if, for example, an elongated object such as a straw is inserted into otherwise one-way valve 14. Deflation provides reusability to inflatable articles 10 herein described.
  • Enclosed chamber 13 encloses valve 14 within first outer fold 27, inner fold 24, and second outer fold 28, in combination with portions of longitudinal side seals 15L (with seals 15L also referred to herein as "double cross seals").
  • Longitudinal side seals 15L may be made in closely-spaced parallel pairs of seals 15L that may optionally be provided with locator apertures 16 between them, where portions of flexible film 11 have been removed, or slice 33 in the flexible film 11 has been made. Locator apertures 16 assist in filling inflatable articles 10 with air. Lines of perforations 18 may optionally be provided between the closely- spaced pairs of longitudinal side seals 15L so that individual inflatable
  • articles 10 may be separated from other inflatable articles by tearing along line of perforations 18. Paired longitudinal side seals 15L, or a single wide seal, prevents inflatable article 10 from leaking at locator aperture 16 and perforations 18.
  • Locator apertures 16 are "between" such closely-spaced pairs of parallel longitudinal side seals 15L in the sense that they are bounded on both sides by at least a portion of a perimeter seal 15L.
  • Heat seals 15T and 15L are herein referred to as perimeter seals.
  • Valve 14 comprises (i) external valve opening 19 which serves as an air inlet for inflation, (ii) collapsible self-sealing inflation channel 20, and (iii) internal valve passageway 21 connecting inflation channel 20 with enclosed chamber 13.
  • External valve opening 19 is between first outer fold 27 and second outer fold 28, and allows air to flow into collapsible self-sealing inflation channel 20, which is between second film portion 29 and third film portion 30.
  • Self-sealing inflation channel 20 extends (a) transversely across the inflatable article from external valve opening 19 to internal valve passageway 21 , and (b) longitudinally between inner fold 24 and discontinuous internal transverse heat seals 25 of first film portion 29 to second film portion 30.
  • discontinuity of the internal transverse heat seals 25 down the film strand forms external valve opening 19 at locations between discontinuous transverse heat seals 25. Further, discontinuous internal transverse heat seals 25 may be rounded at portion 26 proximate to external valve opening 19, as shown in FIGS. 2, 3, and 8. Rounding the end of transverse heat
  • first film portion 29 can be heat sealed to second film portion 30 at transverse heat seal 12 adjacent inner fold 24, as illustrated in FIGs. 1 , 2, and 3.
  • internal valve opening 21 H is a hole in second film portion 29. Opening 21 H is formed by punching out scrap piece 17H from film 11. In the embodiments illustrated in FIGs.
  • internal valve opening 21 N is a notch resulting from the removal of scrap portion 17N, with the notch extending through both second film portion 29 and the third film portion 30 and along a portion of inner fold 24.
  • FIGs. 4, 5, and 6 illustrate internal valve opening 21 E formed by removal of scrap portion 53E along a portion of inner fold 24, in combination with longitudinal slits 33 made through both second film portion 29 and third film portion 30.
  • internal valve passageway 21 can be made in second film portion 29, or third film portion 30, or as one opening within both second and third film portions 29 and 30, or as two or more openings each being within second film portion 29 or third film portion 30.
  • internal valve passageway 21 is at least one member selected from the group of hole, notch, and slit in at least one member selected from second film portion 29 and third film portion 30.
  • Valve 14 is between second film portion 29 and third film portion 30.
  • the combination of inner fold 24 and first outer fold 27 produces second film portion 29 which extends from inner fold 24 to first outer fold 27.
  • the combination of inner fold 24 and second outer fold 28 produces third film portion 30 which extends from inner fold 24 to second outer fold 28.
  • Second film portion 29 and third film portion 30 together envelop valve 14 which is contained within enclosed chamber 13 by transverse bottom seal 15T and the pair of longitudinal side seals 15L of first film portion 34 to fourth film portion 35, which longitudinal side seals 15L also seal end regions of second and third film portions 29 and 30 to each other as well as to first film portion 34 and fourth film portion 35, thereby closing off valve 14 to prevent valve 14 from communicating with valves 14 of neighboring inflatable articles 10.
  • second outer fold 28 can be offset from first outer fold 27 to provide gutter 31 (see FIG. 8) between first outer fold 27 and second outer fold 28, which gutter 31 aids in filling inflatable article 10 with air.
  • Air flow 32 directed in a direction perpendicular to the lay-flat plane of uninflated inflatable article 10 is deflected into the valve 14 by gutter 31 which extends further outward from first outer fold 27.
  • valve 14 Another feature that may be present in valve 14 is slits 25S, which may be provided along the midline of discontinuous internal transverse heat seals 25. Slits 25S provide a degree of separation between valve 14 from and the remainder of inflatable article 10, and thereby assist in preventing undesired leakage of air from the enclosed chamber 13 of a filled, self-sealed inflatable article upon its vibration and/or flexing in response to applied load or impact.
  • FIG. 6 An additional embodiment of inflatable article 10 is shown in FIG. 6. This embodiment is similar to the other previously described embodiments, but differs in that it uses multiple enclosed chambers 13 with corresponding valves 14. Instead of having one valve 14 and one enclosed chamber 13 per inflatable article 10, there are multiple valves and multiple enclosed chambers per inflatable article 10. This is accomplished by providing narrower enclosed chambers 13 as well as perimeter seals 15 which do not extend between every enclosed chamber 13. This embodiment is configured to be used in wrapping items for shipment.
  • Inflatable articles 10 above are capable of inflation-at-a-distance.
  • airflow 32 opens valve 14 without necessitating contact between inflatable article 10 and any inflation wand, inflation needle, inflation nozzle, or other element to direct air into valve 14 to inflate article 10.
  • Inflation-at- a-distance is depicted in FIG. 8, wherein valve 14 is shown being opened by airflow 32.
  • valve 14 is moved out of the proximity of air flow 32, and second and third film portions 29 and 30 are forced together by the pressure inside chamber 13.
  • inflatable articles 10 may be disposed of, reused, or recycled.
  • the volume of inflatable articles 10 may be reduced dramatically by either rupturing the inflatable articles or by releasing the air from each inflatable article via valve 14. If an elongated object, such as a pen or straw is inserted into the valve 14, the seal created by the self- sealing valve 14 can be temporarily broken. This action will lead to the release of air from the inflatable article 10, thereby deflating it.
  • Reuse of the inflatable articles 10 is relatively simple in that the inflatable articles can be re-inflated without necessitating the use of an inflation needle, as a person may simply blow towards the external valve opening 19 of the valve 14 to refill it.
  • inflatable articles 10 [0093] Having described the features of inflatable articles 10, methods of forming the inflatable articles will now be described. It is to be recognized that it is possible to form inflatable articles 10 in many ways. The following descriptions are meant only to provide examples of possible methods of forming inflatable articles 10. The order of operations could be changed. The manner of carrying out an operation could also be changed. The manufacturing process may not require handwork for assembly. Inflatable articles 10 can be produced using an inline manufacturing process without handwork, reducing production costs and production time.
  • FIG. 9 schematically illustrates a process for forming inflatable article 10, comprising advancing a continuous strand or web 37 of flexible film 11 in machine direction 39 and folding flexible film 11 to make inner fold 24 which extends in a direction parallel to machine direction 39.
  • Inner fold 24 may be formed using folding plow 51 .
  • Inner fold 24 can alternatively be formed by sealing together two separate pieces of flexible film 11 (disclosed herein, but not illustrated), or by both folding and sealing flat film 11 together, using rotary sealer 52U, to form inner fold 24 (as illustrated in FIG. 9) and inner fold heat seal 24 (see FIG. 1 B).
  • first opposing side 56 and second opposing side 58 of folded film web 54 are thereafter heat sealed to each other to produce discontinuous internal transverse heat seals 25 that, together with inner fold 24 and other features, define valve 14.
  • Internal valve opening 21 may be made by forming an aperture in either or both of first film side 56 and second film side 58 of folded film web 54 proximate inner fold 24. This may comprise slicing a slit 21 S in flexible film 11 , punching out a hole in flexible film 11 , cutting off a scrap portion 17 to produce a notch in flexible film 11 , or slicing off scrap portion 53 from flexible film 11 , as illustrated in FIG 1 through 5, described above.
  • the next step is to fold first opposing side 56 of flexible film 11 in a direction to make first outer fold 27 in a direction substantially parallel to machine direction 39, and to provide first film portion 34; and to also fold second opposing side 58 of flexible film 11 to make second outer fold 28 in a direction substantially parallel to machine direction 39, and to provide fourth film portion 35.
  • Folding plows 51 can be used to produce first outer fold 27 and second outer fold 28.
  • First film portion 34 and fourth film portion 35 are then sealed together to produce bottom transverse heat seal 15T and transverse side seals 15L which, together with first and second outer folds 27 and 28, enclose chamber 13.
  • Rotary sealer 52D may be used to form bottom transverse heat seal 15T.
  • Reciprocating sealing bar 41 may be used to form longitudinal side seals 15L.
  • Perimeter seals do not have to be placed at the edges of the first film portion 34 and fourth film portion 35 of inflatable article 10. Rather, “perimeter” describes the perimeter seals' function as providing at least a portion of the boundary defining enclosed chamber 13. Perimeter seals 15T and 15L can be placed near the longitudinal side edges of first film portion 34 and fourth film portion 35, and may also extend between two separate inflatable articles 10. Portions of the length of perimeter seals 15T and 15L may also seal together end regions of first film portion 29 and second film portion 30, to prevent valve 14 from communicating with valves 14 of neighboring inflatable articles 10, as described above.
  • Perimeter longitudinal side seals 15L may have therethrough (or be proximate to) perforations 18, with perforations 18 being provided to allow ease of separation of inflatable articles 10 from one another.
  • Locator apertures 16 may extend between closely spaced pairs of longitudinal side seals 15L (i.e., double cross seals) to allow for engagement with a mechanical registration device 40, as disclosed herein.
  • Perforations 18 and locator apertures 16 may extend directly through the sealed portion of flexible film 11 , or they may extend between two adjacent seals when, for example, perimeter seals 15L comprise a double cross seal. Both such arrangements prevent perforations 18 and locator apertures 16 from piercing enclosed chamber 13, which would prevent inflatable article 10 from maintaining its inflated state.
  • seals 12 and 25 are a generic term encompassing various types of sealing arrangements.
  • seals include welds created by heat sealing or use of adhesive or cohesive bonds.
  • Discontinuous internal transverse heat seals 25 refers to seals that have breaks that leave portions where the second film portion 29 and third film portion
  • the discontinuity may be produced using a continuous heat welder with portions of the first film side 56 and portions of the second film side 58 having a heat-resistant substance, such as heat-resistant ink, between them, e.g., printed onto one or both surfaces which are to be sealed together.
  • a heat-resistant substance such as heat-resistant ink
  • inflation channel 20 of valve 14 may be formed without the use of heat-resistant ink. The absence of heat-resistant ink is beneficial since most heat-resistant inks develop a small amount of tackiness when heat is applied.
  • This tack is usually not problematic for inflatable articles 10 with conventional valves, as a rigid structure such as an inflation needle is typically used to force the valve channel open just prior to inflation. However, when performing inflation at a distance, airflow alone opens valve channel 20. In order facilitate non-contact valve opening using only relatively low pressure airflow for inflation, introduction of increased tack should be avoided.
  • discontinuous internal transverse heat seals 25 are provided in valve 14 without utilizing heat-resistant ink in channel 20 of valve 14.
  • Discontinuous internal transverse heat seal 25 can be made in a discontinuous manner by using a heated roller with gaps in the sealing surface corresponding with the desired discontinuities.
  • a reciprocating heated sealing bar 41 with gaps in the sealing surface corresponding to the discontinuities could also be used.
  • a sealing bar without gaps in the sealing surface could be used in conjunction with a no-tack type of heat resistant material such as pieces of
  • TEFLON ® placed at each discontinuity.
  • a heated sealing bar 41 without gaps could be used, in combination with an intermittent advance of the flexible film 11 which may be accomplished by a variety of known means such as by application of a dancer bar, to allow for discontinuous transverse heat seals 25.
  • the discontinuous internal transverse heat seals 25 may have a rounded portion 26, as previously discussed, which serves to prevent tears of flexible film 11. In the process of FIG. 9, this can be accomplished by spot-sealing first film side 56 to second film side 58 proximate to the end of a seal 25. Also, an additional step can include slicing a slit 33 down the center along the length of each of seals 25. As previously discussed, this assists in preventing valve 14 from undergoing accidental opening after inflation.
  • the finished product from the above-described process may take the form of a continuous web of inflatable articles 10. Such a continuous web may then be packaged in many different manners so as to be ready for use. One such manner is to roll the continuous web into a roll 38, as shown in FIGS. 10-13.
  • FIG. 16 Another way to package the inflatable articles 10 is to fold them into a folded form 47, as shown in FIG. 16. Alternately, the continuous web may be cut into individual inflatable articles 10, and then connected together in the form of a cartridge 36, as shown in FIGS. 14, and 15. In one such embodiment, each of the third film portions 30 of inflatable article 10 may be attached to a fourth film portion 35 of an adjacent inflatable article, as shown in FIGS. 14 and 15.
  • a folded form 47 as shown in FIG. 16.
  • the continuous web may be cut into individual inflatable articles 10, and then connected together in the form of a cartridge 36, as shown in FIGS. 14, and 15.
  • each of the third film portions 30 of inflatable article 10 may be attached to a fourth film portion 35 of an adjacent inflatable article, as shown in FIGS. 14 and 15.
  • cartridges 36 can be held together by holder 42, which can take the form of a clamp, staple, rod, etc. If a holder 42 such as a staple is used, the holder must extend through a portion of inflatable article 10 other than through any portion of the chamber wall so as to not puncture enclosed chamber 13.
  • FIGS. 10-13 are directed to an embodiment of inflation device 43 which can be used to inflate inflatable articles 10.
  • Inflation device 43 comprises housing 44, inflatable article holder 42, and a source of pressurized air 45 having air outlet 46.
  • Inflation device 43 is designed to dispense a continuous web of inflatable articles, shown in FIGS. 10-13 as roll 38 of inflatable articles 10.
  • Other forms of webs of inflatable articles 10 could also be inflated such as a folded form 47 of the inflatable articles illustrated in FIG. 16.
  • inflation device 43 may further include mechanical registration device 40 for engaging locator apertures 16 in inflatable articles 10.
  • Mechanical registration device 40 and locator apertures 16 can take a number of different corresponding forms.
  • locator aperture 16 could be a slit, as shown in FIGS. 2, 3, and 7 or a rectangular shape with rounded corners, such as is shown in FIGS. 1 , 4, 5, and 13.
  • Mechanical registration device 40 takes a corresponding shape such as the rectangular embodiment with rounded corners as shown in FIG. 13, so as to temporarily engage locator aperture 16 and hold inflatable article 10 in place.
  • outlet 46 of source of pressurized air 45 is proximate to valve 14 when the inflatable article 10 holder 42 dispenses the inflatable article. This can be facilitated through use of mechanical registration device 40.
  • Mechanical registration device 40 temporarily engages locator apertures 16 which may be located in longitudinal side seals 15L separating multiple inflatable articles 10. Hence mechanical registration device 40 temporarily holds inflatable article 10 in such a position so as to allow outlet 46 of the source of pressurized air 45 to be near valve 14 of inflatable article 10 and fill it with air.
  • a visual indicator may be used to determine when valve 14 is proximate to outlet 46 of the source of pressurized air 45.
  • a line can be drawn on the inflatable article 10 that matches up to a line on inflation device 43 when the valve 14 is proximate to outlet 46 of the source of pressurized air 45.
  • an indicator on the inflation device 43 may line up with longitudinal side seals
  • inflation device 43 can inflate and dispense continuous web of inflatable articles 10 held by inflatable article holder 42.
  • FIG. 16 Another such embodiment is shown in FIG. 16.
  • inflatable article holder 42 is designed to hold a continuous web of inflatable articles 10 that are in folded form 47 and held by pair of rods 48.
  • Rods 48 are a type of mechanical registration device 40 that function similarly to the above-described embodiments in that they help temporarily locate valve 14 of inflatable article 10 proximate to the outlet 46 of a source of pressurized
  • FIGS. 14 and 15 alternate embodiments are contemplated such as the embodiments shown in FIGS. 14 and 15 wherein the inflatable article 10 inflation device 43 is designed to fill inflatable articles which are packaged together in cartridge 36.
  • These embodiments can make use of an alternative type of inflatable article holder 42 in the form of a clamp, which holds the inflatable articles together as cartridge 36.
  • the holder 42 can hold each of the inflatable articles 10 together by engaging second outer fold 28 that extends beyond a first outer fold 27 in the flexible film, as shown in FIGS. 14 and 15. This allows valve 14 of the outermost of inflatable articles 10 to remain exposed such that it can receive an air
  • Methods of inflating inflatable articles 10 include inflation without physical contact between the outlet 46 of the source of pressurized air 45 and the inflatable article 10. Further, the methods may use air flow 32 that is either high pressure or low pressure. Low pressure air flow 32 refers to air flow which may be produced by a fan or blower or human-powered inflation (e.g., whistling or blowing), whereas high pressure air flow refers to compressed air.
  • the methods of inflating inflatable articles 10 are largely described in terms of manual human operation of the inflation device 43.
  • the inflation device 43 may be fully or partially automated.
  • a drive motor may be used to feed the continuous web of inflatable articles 10 through the inflation device 43.
  • the inflation device 43 may further be equipped with a controller that automatically fills the inflatable articles 10 with the desired amount of air.
  • mechanical registration device 40 and locator apertures 16 may or may not be necessary, as the drive motor controller could stop the advance of the web of inflatable
  • Inflation device 43 may be oriented in a number of different ways.
  • the inflation device 43 may be wall-mounted, as shown in FIGS. 1 1 and 13, or table-mounted, as shown in FIG. 12.
  • FIGS. 10-13 and 16 With regard to the embodiments of the inflatable article 10 inflation device 43 shown in FIGS. 10-13 and 16, their operation will now be described.
  • An operator may first secure a continuous web of inflatable articles 10 with the holder 42.
  • the operator can then turn on the source of pressurized air 45, which may constitute a blower.
  • the operator may pull on the first inflatable article 10 until a valve 14 in the inflatable article is proximate to outlet 46 of the source of pressurized air 45.
  • the continuous web of inflatable articles will stop when the mechanical registration device engages a locator aperture, and the inflatable article inflation device is designed to have the outlet 46 of the source of pressurized air 45 proximate to the valve 14 at this point.
  • the inflatable article 10 or the inflation device 43 or both may have a visual indicator which reaches a point of optical alignment when valve 14 is proximate to outlet 46 of the source of pressurized air 45.
  • the operator may simply pull on the continuous web of inflatable articles 10 and not stop each time a valve 14 passes the outlet 46 of the source of pressurized air 45. This is possible when the source of pressurized air 45 emits sufficient air flow 32.
  • valve 14 and outlet 46 When valve 14 and outlet 46 are thus proximate to each other, the source of pressurized air 45 will fill the inflatable article 10 with air.
  • "Proximate" here means that the valve 14 and the outlet 46 of the source of pressurized air 45 are located relative to one another such that an air flow 32 from the outlet reaches the valve and is able to penetrate the valve and enter into an enclosed chamber 13 in the inflatable article 10, as shown in FIG. 8.
  • the source of pressurized air 45 does not have to operate at a high pressure nor does the outlet 46 require contact with inflatable article 10. Instead, the source of pressurized air 45 may emit low pressure air flow 32, and outlet 46 may be physically separated from inflatable article 10. Once inflatable article 10 has reached the desired level of fullness, the operator can then either repeat the previous steps by pulling on the continuous web of inflatable articles to access the next inflatable article, or the operator can tear the filled inflatable article off from the remainder of the continuous web of inflatable articles.
  • Filling inflatable article 10 may automatically lift the locator aperture 16 off the mechanical registration device 40 such that the inflation device 43 is ready to advance the continuous web of inflatable articles 10 and fill the next inflatable article 10. Also, mechanical registration device 40 may be joined to the remainder of the inflation device 43 by a hinge or flexible connector such that the inflation of the inflatable article 10 dislodges the mechanical registration device from the locator aperture 16.
  • the amount of air that fills inflatable article 10 may be controlled in a number of ways.
  • One such method visual inspection of inflatable
  • inflatable article 10 whereby the operator removes inflatable article from proximity with the outlet 46 of the source of pressurized air 45 when the inflatable article 10 is filled with the desired amount of air.
  • inflatable article 10 may automatically release from the inflation device 43 when mechanical registration
  • An alternative or additional way of controlling the level of inflation is to use inflation restriction structures to control the dimensions of inflatable article 10 as it inflates.
  • Inflation restriction structures can take the form of plates or bars between which the inflatable articles 10 inflate. As inflatable articles 10 fill, the inflation restriction structure can restrict the dimensional expansion of the inflatable articles, and hence limit the amount of air that fills the inflatable articles.
  • the operation may begin by placing cartridge 36 of inflatable articles 10 in holder 42.
  • Inflatable articles 10 may be connected to one another prior to insertion in holder 42, as through use of a staple, heat seal, or adhesive, or the holder can operate to clamp them together.
  • the operator may then turn on the source of pressurized air 45, which results in air flow 32.
  • the outlet 46 of the source of pressurized air 45 can be aimed at valve 14 of the outermost of inflatable articles 10.
  • outlet 46 may be aimed at holder 42, which can comprise diverter 50 to direct air flow 32 toward valve 14 of the outermost inflatable article 10.
  • the operator removes the inflatable article. Removing the filled inflatable article 10 may involve pulling the inflatable article out from holder 42. The process can then be repeated to inflate additional inflatable articles 10. Examples
  • each of which was used to produce a plurality of inflatable self-sealing articles from a film strand which was folded and sealed in accordance with the process illustrated in FIG. 9, described above.
  • Each film had a total thickness of 1 .17 mils.
  • Each article had the same overall size, i.e., an uninflated width of 20 cm and an uninflated length of 25.4 cm, with the articles being generally in accordance with inflatable articles 10 as illustrated in FIG. 2, described above.
  • Each article was inflated with air to an internal pressure of from 0.1 to 5 psi (depending upon inflation setting on inflation device), with the article taking on the shape of an inflated pillow.
  • each inflated article was determined by: placing a lower side of the inflated article on top of and in contact with a bottom platen of a parallel platen test device; lowering the upper platen into contact with the applying a force of 1200 grams to the inflated article with the upper platen; and measuring the distance between the platens as corresponding with the height of the inflated article.
  • a total of 5 inflated articles were placed into a wooden air loss box made from plywood about 1 .9 cm thick.
  • the air loss box had a bottom, an open top, and 1 .9 cm thick plywood side walls and partial end walls connecting the side walls to each other and extending all the way to the top of the side walls, but extending down towards the bottom but coming no closer to the bottom than 7or 8
  • a second box made from the same kind of plywood was made smaller than the air loss box, i.e. , small enough to fit into the air loss box with about a 10 mm gap all the way around between the inside of the air loss box second box.
  • the second box had a bottom and four sides with each side being about 15 cm high. The second box was used when testing the inflated articles under load.
  • Table 2 above, provides 24-hour inflation retention values for Film Nos. 1 , 2, 3, 4, and 5. Each film had a thickness of 1 .17 mils. Each film was a multilayer film with three layers. Each inside layer had a thickness of 0.31 mil, a core layer with a thickness of 0.51 mil, and an outside layer with a thickness of 0.35 mil.
  • the polymer used in the films included various different polyethylene materials, including linear low density polyethylene, low density polyethylene, medium density polyethylene, and single site catalyzed ethylene alpha-olefin copolymer.
  • the central core layer of each of the five films had the same thickness and the same polymeric composition.
  • the inside and outside layers of the films varied with each other in terms of the amount of antiblock particles and the average particle size of the antiblock particles, and the amount of slip agent present in the film, and the relative amounts of the different kinds of ethylene- based polymers present therein.
  • the 24 hour inflation retention testing was used to distinguish the relative amount of air retention for each of Film Nos. 1 , 2, 3, 4, and 5.
  • Film No. 5 which exhibited the best air retention performance, was symmetrical in terms of layer composition (outside layers made from identical blends, with the outside layer being 13% thicker than the inside layer.
  • Film No. 6 exhibited improved 72-hr inflation retention under load than Film No. 1 (89.4% air retention versus 86.2% air retention). Film No. 6 also had somewhat higher level of antiblock in the outside layer and somewhat more slip agent on a whole film basis, versus Film No. 1 . Film No. 6 had an A/B/A structure with the film layers being of symmetrical composition.
  • Table 4 provides 72-hour inflation retention values for Film Nos. 1 and 7-16.
  • Each of Film Nos. 1 and 7-16 had a thickness of 1 .17 mils.
  • Each film was a multilayer film having three layers. Each film had an inside layer having a thickness of 0.31 mil, a core layer with a thickness of 0.51 mil, and an outside layer with a thickness of 0.35 mil.
  • Various polyethylenes were present in Film Nos. 1 and 7-16, including linear low density polyethylene, low density polyethylene, medium density polyethylene, and single site catalyzed ethylene/alpha-olefin copolymer.
  • the central core layer of the films included varying amounts of medium density polyethylene (i.e., MDPE, having a density of 0.931 g/cc), which polymer increased film stiffness with increasing weight percent in the film.
  • MDPE medium density polyethylene
  • each of Film Nos. 7-16 had a symmetrical structure in terms of outer layer composition (including slip and antiblock levels), with the outside layer being about 13% thicker than the inside layer.
  • the best inflation retention level under 3-lb load for 72 hours was 95.0% with a standard deviation of 2.04, exhibited by the self-sealing inflatable article made from Film No.10, which contained 0% MDPE, and which had an outside layer containing antiblock at a level of 1.5 wt % with an average particle size of 5 microns and a particle size distribution span of 0.56.
  • Lesser 72-hr inflation retention under load performance was obtained from inflatable articles made from Film Nos.13, 7, 9, and 15, which were at 94.8%, 94.4%, 94.4%, and 92.8%, respectively, with standard deviations of 2.41, 2.65, 3.75, and 3.77, respectively.
  • the three best self-sealing inflated articles with respect to inflation retention under load for 72 hours were made from Film Nos.7, 10, and 13.
  • Each of these three films had an outside layer containing 1.5 wt % antiblock having an average particle size of 5 microns and a particle size distribution span of 0.562.
  • Film No.15 exhibited a low inflation rate (only 32%) after aging at 120F for 72 hours. This was believed to be due to the presence of 33 wt % MDPE (total film basis), as an even worse inflation rate of 30% was seen for the inflatable articles made from Film No.16, which had an MDPE level of 44% on a total film basis.
  • the worst inflation retention level under 3-lb load for 72 hours was 86.4% with a standard deviation of 7.53, exhibited by the self-sealing inflatable article made from Film No.1 , which had an antiblock level of only about 26% of the antiblock level present in Film No. 10.
  • the next worst were Film Nos. 12, 14, 16, and 1 1 , which exhibited an inflation retention level under 3-lb load for 72 hours of 88.1 %, 88.2, 88.7%, and 89.1 %, respectively, with standard deviations of 3.88, 4.20, 3.70, 5.40, and 4.64, respectively.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un article gonflable fabriqué à partir d'un film souple et comportant une chambre gonflable et une valve unidirectionnelle à fermeture hermétique automatique. Le film fournit un premier côté de chambre et un deuxième côté de chambre. Une chambre gonflable est formée par des joints périphériques du premier côté de chambre au deuxième côté de chambre. La valve unidirectionnelle à fermeture hermétique automatique comporte un canal de gonflage pliable à fermeture hermétique automatique et un passage de valve interne dans la chambre gonflable. Au moins une partie du film constituant la valve unidirectionnelle comporte une couche externe contenant un antibloc particulaire en une quantité d'au moins 0,5 % en poids, l'antibloc particulaire ayant une taille de particule moyenne comprise entre 2 et 9 microns, et une plage de répartition granulométrique de ≤ 3,0.
PCT/US2018/035809 2017-06-06 2018-06-04 Article gonflable à fermeture hermétique automatique présentant une rétention de fluide améliorée sous charge WO2018226561A1 (fr)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100096290A1 (en) * 2008-10-22 2010-04-22 Sealed Air Corporation Inflatable Structure for Packaging and Associated Apparatus and Method
US20100101970A1 (en) * 2008-10-22 2010-04-29 Sealed Air Corporation (Us) Inflatable Structure For Packaging And Associated Apparatus And Method
US20110247725A1 (en) * 2008-10-22 2011-10-13 Sealed Air Corporation (Us) Inflatable structure for packaging and associated apparatus and methods

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100096290A1 (en) * 2008-10-22 2010-04-22 Sealed Air Corporation Inflatable Structure for Packaging and Associated Apparatus and Method
US20100101970A1 (en) * 2008-10-22 2010-04-29 Sealed Air Corporation (Us) Inflatable Structure For Packaging And Associated Apparatus And Method
US20110247725A1 (en) * 2008-10-22 2011-10-13 Sealed Air Corporation (Us) Inflatable structure for packaging and associated apparatus and methods

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