WO2020227587A1

WO2020227587A1 - Inflatable web materials and seal structures thereof

Info

Publication number: WO2020227587A1
Application number: PCT/US2020/031986
Authority: WO
Inventors: Janet Rivett; Morgan R. STEWART; Jessica DENSON; Robert J. O'dowd
Original assignee: Sealed Air Corporation (Us)
Priority date: 2019-05-09
Filing date: 2020-05-08
Publication date: 2020-11-12

Abstract

A web material includes two juxtaposed sheets and seals between the two juxtaposed sheets. The two juxtaposed sheets are arranged to form an inflatable web. The inflatable web comprises two longitudinal edges and chambers located between the two longitudinal edges. The seals define sides of the chambers. The seals have a pattern so that the chambers formed by the seals include cells and interconnecting channels. The web material has a cell wide point based on a distance between consecutive ones of the seals. The web material has a seal width based on a distance between consecutive ones of the seals. A ratio of the seal width of the web material to the cell wide point of the web material is in a range from about 1:4 to about 1:15.

Description

INFLATABLE WEB MATERIALS AND SEAL STRUCTURES THEREOF

SPECIFICATION

BACKGROUND

[0001] The present disclosure is in the technical field of inflatable web materials.

More particularly, the present disclosure is directed to web materials having seal structures that enable adherence of labels to the web materials after inflation.

[0002] Consumers frequently purchase goods from mail-order or internet retailers, which package and ship the goods to the purchasing consumer via a postal service or other carrier. Millions of such packages are shipped each day. These items are normally packaged in small containers, such as boxes or envelopes. To protect the items during shipment, they are typically packaged with some form of protective dunnage that may be wrapped around the item or stuffed into the container to prevent movement of the item and to protect it from shock.

[0003] Common types of mailing envelope are sometimes referred to as“mailers.” In some cases, these mailers have cushioning to provide some level of protection for the objects transported therein. The outer walls of cushioned mailers are typically formed from protective materials, such as Kraft paper, cardstock, polyethylene- coated paper, other paper-based materials, polyethylene film, or other resilient materials. The inner walls of cushioned mailers are lined with cushioning materials, such as air cellular material (e.g., BUBBLE WRAP™ air cellular material sold by Sealed Air Corporation), foam sheets, or any other cushioning material. The outer walls are typically adhered (e.g., laminated) to the cushioning material when forming the mailers. [0004] When goods are shipped in rigid containers, such as corrugated cardboard boxes, dunnage material is typically added to the containers to take up some of the void space within the containers. Inflated cushions, pillows, or other inflated containers are common void fill materials that are either placed loose in a container with an object or wrapped around an object that is then placed in a container. The cushions protect the packaged item by absorbing impacts that may otherwise be fully transmitted to the packaged item during transit, and also restrict movement of the packaged item within the carton to further reduce the likelihood of damage to the item. Another common form of void fill material is paper, such as Kraft paper, that has been folded or crumped into a low-density, three-dimensional pad or wad that is capable of filling void space without adding significant weight to the container.

[0005] It would be advantageous to automate the packaging process to minimize the amount of time required to package objects properly. However, given the wide variety of ways which objects can be packaged for shipping, automation of the packaging process can be challenging.

SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In a first embodiment, a web material includes two juxtaposed sheets arranged to form an inflatable web. The inflatable web comprises two longitudinal edges and chambers located between the two longitudinal edges. The web material further includes seals between the two juxtaposed sheets that define sides of the chambers. The seals have a pattern so that the chambers formed by the seals include cells and interconnecting channels. The web material has a cell wide point based on a distance between consecutive ones of the seals. The web material has a seal width based on a distance between consecutive ones of the seals. A ratio of the seal width of the web material to the cell wide point of the web material is in a range from about 1 :4 to about 1 : 15.

[0008] In a second embodiment, the chambers of the first embodiment extend across the web material in a transverse direction.

[0009] In a third embodiment, the chambers of the second embodiment are arranged in a pattern that generally repeats in a longitudinal direction, and wherein the longitudinal direction is substantially perpendicular to the transverse direction.

[0010] In a fourth embodiment, the chambers of any of the previous embodiments are arranged so that a first chamber and a second chamber are adjacent to each other and the first and second chambers are offset so that the cells in the first chamber are aligned with the interconnecting channels of the second chambers.

[0011] In a fifth embodiment, the pattern of the seals of any of the previous embodiments is a sinusoidal pattern that repeats.

[0012] In a sixth embodiment, the sinusoidal pattern of the seals of the fifth embodiment is configured such that adjacent ones of the seals are mirrors of each other and the cells in the chambers are circular or ovoidal in shape.

[0013] In a seventh embodiment, the pattern of the seals of any of the previous embodiments is a line pattern that repeats.

[0014] In an eighth embodiment, the line pattern of the seals of the seventh embodiment is configured such that adjacent ones of the seals are mirrors of each other and the cells in the chambers are polygonal in shape.

[0015] In a ninth embodiment, the ratio of the seal width of the web material to the cell wide point of the web material of any of the previous embodiments is in one of the following ranges: from about 1 :4 to about 1 :12, from about 1 :4 to about 1 :10, from about 1 :4 to about 1 :8, or from about 1 :4.5 to about 1 :6. [0016] In a tenth embodiment, 10. the ratio of the seal width of the web material to the cell wide point of the web material of any of the previous embodiments is about 1 :5.

[0017] In an eleventh embodiment, the cell wide point of the web material of any of the previous embodiments is less than or equal to one or more of about 1.0 inches, 0.9 inches, 0.8 inches, 0.7 inches, 0.6 inches, or 0.5 inches.

[0018] In a twelfth embodiment, the cell wide point of the web material of any of the previous embodiments is one or more of a largest cell wide point of any of the cells, an average cell wide point of all of the cells, or an average cell wide point of the chambers.

[0019] In a thirteenth embodiment, the seal width of the web material of any of the previous embodiments is one or more of a largest seal width of any of the seals, an average seal width of the seals, or an average seal width of the seals.

[0020] In a fourteenth embodiment, a method includes inflating chambers of a web material. The web material includes two juxtaposed sheets arranged to form an inflatable web. The inflatable web comprises two longitudinal edges, and wherein the chambers are located between the two longitudinal edges. The web material also includes seals between the two juxtaposed sheets that define sides of the chambers. The seals have a pattern so that the chambers formed by the seals include cells and interconnecting channels. The web material has a cell wide point based on a distance between consecutive ones of the seals. The web material has a seal width based on a distance between consecutive ones of the seals. A ratio of the seal width of the web material to the cell wide point of the web material is in a range from about 1 :4 to about 1 :15. The method further comprises sealing closed the inflated chambers of the web material and adhering a label to an exterior side of portions of the cells of the chambers. [0021] In a fifteenth embodiment, the method of the fourteenth embodiment further includes forming the web material into a pouch, receiving an object into the pouch, and closing the pouch to form a package of the web material with the object located therein. [0022] In a sixteenth embodiment, the pouch of the fifteenth embodiment is closed to form the package either after or while the label is adhered to the exterior side of the portions of the cells of the chambers.

[0023] In a seventeenth embodiment, after the label of any of the fourteenth to sixteenth embodiments is adhered to the exterior side of the portions of the cells of the chambers, one or more gaps exist between the label and the web material.

[0024] In an eighteenth embodiment, the one or more gaps of the seventeenth embodiment are at locations of one or more of the seals.

BRIEF DESCRIPTION OF THE DRAWING

[0025] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0026] Fig. 1 depicts an example of a package for packaging an object that can be formed from an inflatable or an inflated web material that can be formed into a pouch for packaging an object, in accordance with embodiments disclosed herein;

[0027] Fig. 2 depicts an example of the package shown in Fig. 1 with a label applied thereon, in accordance with embodiments disclosed herein;

[0028] Figs. 3A and 3B depict front and cross-sectional side views, respectively, of a web material in an unfolded state, in accordance with embodiments disclosed herein; [0029] Fig. 3C depicts a partial view of the web material shown in Figs. 3A and 3B, where the partial view shows portions of a number of the chambers, in accordance with embodiments disclosed herein;

[0030] Figs. 4A and 4B depict partial front and partial lower perspective views, respectively, of the web material shown in Figs. 3A and 3B in an inflated state with a label adhered thereon, in accordance with embodiments disclosed herein; and

[0031] Figs. 5A and 5B depict examples of web materials that have seals with non- sinusoidal seal patterns, in accordance with embodiments disclosed herein.

DETAILED DESCRIPTION

[0032] The present disclosure describes embodiments of web materials having seal structures that enable adherence of labels to the web materials after inflation. In some embodiments, a web material includes two juxtaposed sheets and seals between the two juxtaposed sheets. The two juxtaposed sheets are arranged to form an inflatable web. The inflatable web comprises two longitudinal edges and chambers located between the two longitudinal edges. The seals define sides of the chambers. The seals are nonlinear and have a pattern so that the chambers formed by the seals include cells and interconnecting channels. The web material has a cell wide point based on a distance between consecutive ones of the seals. The web material has a seal width based on a distance between consecutive ones of the seals. A ratio of the seal width of the web material to the cell wide point of the web material is in a range from about 1 :4 to about 1 :15.

[0033] Depicted in Fig. 1 is an example of a package 10 for packaging an object that can be formed from an inflatable or an inflated web material that can be formed into a pouch for packaging an object. In the depicted embodiment, the package 10 is formed from a web material 100 that is an inflated air cellular material. As used herein, the term“air cellular material” herein refers to bubble cushioning material, such as BUBBLE WRAP® air cushioning material sold by Sealed Air Corporation, where a first film or laminate is formed (e.g., thermoformed, embossed, calendared, or otherwise processed) to define a plurality of cavities and a second film or laminate is adhered to the first film or laminate in order to close the cavities. Examples of air cellular materials are shown in U.S. Patent. Nos. 3,142,599, 3,208,898, 3,285,793,

3,508,992, 3,586,565, 3,616,155, 3,660,189, 4,181 ,548, 4,184,904, 4,415,398, 4,576,669, 4,579,516, 6,800,162, 6,982,1 13, 7,018,495, 7,165,375, 7,220,476,

7,223,461 , 7,429,304, 7,721 ,781 , and 7,950,433, and U.S. Published Patent Application Nos. 2014/0314978 and 2015/00751 14, the disclosures of which are hereby incorporated by reference in their entirety.

[0034] As used herein, an“object” may comprise a single item for packaging or grouping of several distinct items where the grouping is to be in a single package. Further, an object may include an accompanying informational item, such as a packing slip, tracking code, a manifest, an invoice, or printed sheet comprising machine-readable information (e.g., a bar code) for sensing by an object reader (e.g., a bar code scanner). In some embodiments, each of the objects includes an object identifier. In some examples, the object identifier includes one or more of a barcode, a quick response (QR) code, a radio frequency identification (RFID) tag, any other form a machine-readable information, human-readable information, or any combination thereof.

[0035] The web material 100 includes a first longitudinal edge 102 and a second longitudinal edge (not visible in Fig. 1 ). In the depicted embodiment, the web material has been folded so that the second longitudinal edge is located behind the first longitudinal edge 102. Between the first longitudinal edge 102 and the second longitudinal edge are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers 106. In the depicted embodiment, the chambers 106 are in an inflated state. In the depicted embodiment, each of the chambers 106 extends substantially transversely across the web material 100 and the pattern of the chambers 106 generally repeats in the longitudinal direction.

[0036] In the depicted embodiment, each of the chambers 106 includes a port 108 that. The ports 108 are located proximate the first longitudinal edge. The juxtaposed sheets are sealed together such that each of the chambers 106 has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers 106 are capable of being inflated by inserting a gas (e.g., air) through the ports 108. Once the chambers 106 are inflated, the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers 106. In the depicted embodiment, a pair of adjacent chambers 106 are offset so that the cells of one of the chambers 106 are aligned with the interconnecting channels of a subsequent one of the chambers 106.

[0037] To aid in inflation of the chambers 106, the web material 100 includes a common channel 1 12. In the depicted embodiment, the common channel 1 12 is in fluid communication with the chambers 106. In some embodiments, a nozzle can be inserted in the common channel 1 12 and direct a gas into the common channel 1 12. The gas inserted into the common channel 1 12 can pass through the ports 108 to inflate the chambers 106. In some embodiments, the nozzle may remain fixed while located within the common channel 1 12 and the web material 100 is moved longitudinally such that the nozzle sequentially inflates the chambers 106. Coupled to the nozzle may be a sealing device configured to close (e.g., seal closed) the ports 108 after inflation of the chambers 106.

[0038] In the depicted embodiments, the web material 100 is folded about a longitudinal fold 1 14 and formed into the package 10 for holding and cushioning an object. In some embodiments, the web material 100 can be folded, inflated, and transversely sealed to form an inflated pouch. An object can be inserted into the pouch and then the pouch can be closed to form a package around the object.

Examples of systems and methods of forming a pouch and then a package in this manner are described in U.S. Patent Application No. 62/783,250, the contents of which are hereby incorporated by reference herein by reference in their entirety. In some embodiments, the web material 100 is formed from a material that is suitable for shipping the object. For example, the web material 100 may be opaque. [0039] To inflate the chambers 106, a nozzle can insert gas into common channel 112 so that the gas passes through the ports 108 and into the chambers 106. After the chambers 106 are inflated, the ports 108 are sealed to maintain the chambers 106 in an inflated state. In the depicted embodiment, the chambers 106 are sealed by a longitudinal seal 130 that passes through the juxtaposed film plies at the ports 108. In some embodiments, the web material 100 is folded about the longitudinal fold 1 14 prior to inflation of the chambers 106.

[0040] After the web material 100 is inflated, the package 10 can be formed. In some embodiments, the longitudinal fold 1 14 is at the transverse middle of the web material so that one transverse half of the web material 100 is visible in Fig. 1 and the other transverse half of the web material 100 is located behind the first transverse half. At this point, transverse seals 12 and 14 can be formed in the two halves of the web material 100. The web material 100 can also be transversely cut outside of the transverse seals to form sides 16 and 18 of the package 10. With the transverse seals 12 and 14 formed and the sides 16 and 18 cut, the web material 100 is in the form of a pouch with the top open. An object can be placed in the pouch and then the closing seal 20 can be made in the pouch to close the object inside of the pouch. In the depicted embodiment, the closing seal 20 is located below the longitudinal seal 130 that closes the chambers 106. In other embodiment, the closing seal 20 may be located above the longitudinal seal 130 that closes the chambers 106.

[0041] In some embodiments, the package 10 formed from the web material 100 is suitable for shipping the object. For example, the web material 100 may be opaque. In another example, the transverse seals 12 and 14 and closing seal 20 are sufficiently strong to hold the package 10 closed while the package 10 experiences the effects associate with shipping the package 10 (e.g., jostling, dropping, handling, etc.). The use of the package 10 as both a shipping container and cushioning material reduces overall waste associated with shipping. For example, shipping the object does not require an outer container (e.g., a corrugated box, etc.) and cushioning material (e.g., air cellular material, paper dunnage, etc.) placed inside of the outer container.

[0042] In some embodiments, the longitudinal seal 130 is configured to hold the package 10 closed during the shipping of the package 10. In some embodiments, the longitudinal seal 130 is capable of being opened by a recipient of the package 10 without the use of tools. For example, in some cases, a recipient can grasp both sides of the web material 100 below the longitudinal seal 130 and pull the sides of the web material 100 apart. This two-handed outward pulling motion may induce sufficient force on the longitudinal seal 130 to cause the longitudinal seal 130 to open, much like the opening of food pouches (e.g., potato chip bags) open due to two-handed outward pulling forces. In some embodiments, such as that shown in Fig. 2, the longitudinal seal 130 is located above the closing seal 20 that seals closed the chambers 106. In this way, when the longitudinal seal 130 is opened, the closing seal 20 remains in place and continues to seal closed the chambers 106 after the longitudinal seal 130 is opened. This allows the package 10 to be reused if needed (e.g., for a return shipment).

[0043] In order for the package 10 to be used for shipping the container, the package 10 needs to be able to hold identifying information, such as a shipping label.

Depicted in Fig. 2 is an example of the package 10 with a label 50 applied thereon. As can be seen in Fig. 2, the label 50 is applied to the package 10 over a number of the inflated cells in some of the chambers 106. In the depicted embodiment, the cells in the chambers 106 are in the form of“bubbles” that have contoured tops.

With many bubble-shaped air cellular materials, labels do not remain adhered to the contoured tops of bubbles very well in part because of the relatively low surface area of the bubbles that contacts the adhesive side of the label. The problem of poor adhesion of the label 50 is amplified when the label 50 is a shipping label on the package 10. The maltreatment endured by the package 10 during shipping (e.g., jostling, dropping, handling, etc.) can easily dislodge (either partially or entirely) the label 50 from the surface of the package 10 or tear the label 50 on the surface of the package 10, thereby rendering the package potentially unidentifiable and/or further unshippable. It would be advantageous for an air cellular material to be formed in a way that a label can be sufficiently adhered to the tops of bubble cells that the label will remain on the package 10 during shipping without being torn.

[0044] Depicted in Figs. 3A and 3B are front and cross-sectional side views, respectively, of a web material 200 having a cellular pattern to which a label can be adhered after inflation. In the depicted embodiment, the web material 200 is in an unfolded state. The web material 200 includes a first longitudinal edge 202 and a second longitudinal edge 204. Between the first and second longitudinal edges 202 and 204 are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers 206. In the depicted embodiment, the chambers 206 are in an uninflated state and the chambers 206 are capable of being inflated. In the depicted embodiment, each of the chambers 206 extends substantially transversely across the web material 200 and the pattern of the chambers 206 generally repeats in the longitudinal direction.

[0045] In the depicted embodiment, each of the chambers 206 includes a port 208 that is open and a distal end 210 that is closed. The ports 208 are located proximate the first longitudinal edge 202 and the distal ends 210 are located proximate the second longitudinal edge 204 so that the ports 208 and the distal ends 210 extend substantially transversely across the web material 200. The juxtaposed sheets are sealed between the ports 208 and the distal ends 210 such that each of the chambers 206 has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells. The chambers 206 are capable of being inflated by inserting a gas (e.g., air) through the ports 208. Once the chambers 206 are inflated, the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers 206. In the depicted embodiment, a pair of adjacent chambers 206 are offset so that the cells of one of the chambers 206 are aligned with the interconnecting channels of a subsequent one of the chambers 206. [0046] The web material includes a first channel 212 and a second channel 222.

The first channel 212 is located proximate the first longitudinal edge 202 and the second channel 222 is located proximate the second longitudinal edge 204. In the depicted embodiment, each of the first and second channels 212 and 222 is a “closed” channel because the two sides of the first channel 212 are connected at the first longitudinal edge 202 and the two sides of the second channel 222 are connected at the second longitudinal edge 204. In this way, the first channel 212 forms a loop above the ports 208 and the second channel 222 forms a loop below the distal ends 210. In other embodiments, one or both of the first and second channels 212 and 222 can be an“open” channel where the two sides of the channel do not meet at the longitudinal edge.

[0047] In the depicted embodiment, the first channel 212 is in fluid communication with the chambers 206. In some embodiments, a nozzle can be inserted in the first channel 212 and direct a gas into the first channel 212. The gas inserted into the first channel 212 can pass through the ports 208 to inflate the chambers 206. In some embodiments, the nozzle may remain fixed while located within the first channel 212 and the web material 200 is moved longitudinally such that the nozzle sequentially inflates the chambers 206. Coupled to the nozzle may be a sealing device configured to close (e.g., seal closed) the ports 208 after inflation of the chambers 206. In the depicted embodiment, the second channel 222 is not in fluid communication with the chambers 206. A longitudinal seal 220 is located in the web material 200 between the distal ends 210 and the second channel 222. The longitudinal seal 220 deters any passage of gas between the chambers 206 and the second channel 222.

[0048] In some embodiments, the web material 200 can be folded and formed into a pouch for holding and cushioning an object. In some embodiments, the web material 200 can be folded, inflated, and transversely sealed to form an inflated pouch. An object can be inserted into the pouch and then the pouch can be closed to form a package around the object. In some embodiments, the web material 200 is formed from a material that is suitable for shipping the object. For example, the web material 200 may be opaque.

[0049] Fig. 3C depicts a partial view of the web material 200 that includes portions of a number of the chambers 206. When viewing the depiction in Fig. 3C, the left and right sides of each of the chambers 206 are defined by seals 230. In the depicted embodiment, the seals 230 are nonlinear so that the chambers 206 formed by the seals 230 include cells 232 and interconnecting channels 234. In the depicted embedment, a pair of adjacent chambers 206 are offset so that the cells 232 of one of the chambers 206 are aligned with the interconnecting channels 324 of a subsequent one of the chambers 206. In some embodiments, a pair of adjacent chambers 206 are separated by only one of the seals 230.

[0050] In some embodiments, each of the seals 230 has a repeating pattern in the transverse direction (the vertical direction when viewing the depiction in Fig. 3C). In the depicted embodiment, the seals 230 have a sinusoidal pattern. Adjacent ones of the seals 230 in the depicted embodiment have patterns that are mirrors of each other. In this way, the cells 232 are substantially circular or ovoidal in shape. In other embodiments, the seals 230 can have other types of patterns so that the cells 232 have a different shape. Examples of various seal patterns and cell shapes are provided below.

[0051] Characteristics of the web material 200 can improve the adherability of labels to the web material 200 after inflation of the web material 200. In the depicted embodiment, the cells 232 have a cell wide point wci. In some embodiment, the cell wide point wci is based on a distance between consecutive seals 230. Because the cells 232 in the depicted embodiment are substantially circular or ovoidal, the cell wide point wci of the cells 232 can be defined as the diameter of the circular or ovoidal cells. In other examples, the cell wide point wci of one of the chambers 206 can be defined as the widest point in the longitudinal direction (the horizontal direction when viewing the depiction in Fig. 3C) between the seals 230 in the chamber, the average width of some or all of the cells 232 in the chamber, or any other manner of determining a cell wide point Wei of the cells 232 in the chamber.

As can be seen in Fig. 3C, because pairs of adjacent chambers 206 are offset, the cell wide point Wei of the cells 232 in one of the chambers 206 may not be aligned with the cell wide point Wei of the cells 232 of an adjacent one of the chambers 260. In some embodiments, the web material 200 may have a cell wide point that is defined as one or more of the largest cell wide point Wei of any of the cells 232, an average cell wide point Wei of all of the cells 232, an average cell wide point Wei of the chambers 206, or any variation thereof.

[0052] In the depicted embodiment, the seals 230 also have a seal width wsi. In some embodiment, the seal width wsi is based on a distance between consecutive chambers 206. In the depicted embodiment, the seals 230 have a substantially uniform width and the seal width wsi is that substantially uniform width for each of the seals 230. In other embodiments, the width of an individual one of the seals 230 may vary between the port 208 and the distal end 210. In such a case, the seal width wsi of the seal 230 may be one or more of the average width of the seal 230, the minimum width of the seal 230, or the maximum width of the seal 230. In some embodiments, the web material 200 may have a seal width that is defined as one or more of the largest seal width wsi of any of the seals 230, an average seal width wsi of all of the seals 230, an average seal width wsi of the seals 230, or any variation thereof.

[0053] In some embodiments, the relative characteristics of the seal width wsi and to the cell wide point Wei can influence the adherability of labels to the web material 200 after inflation of the web material 200. In some embodiments, a ratio of the seal width wsi of the web material 200 to the cell wide point Wei of the web material 200 is in a range from about 1 :4 to about 1 : 15. In some embodiments, a ratio of the seal width wsi of the web material 200 to the cell wide point Wei of the web material 200 is in one of the following ranges: from about 1 :4 to about 1 :12, from about 1 :4 to about 1 :10, from about 1 :4 to about 1 :8, or from about 1 :4.5 to about 1 :6. In some embodiments, a ratio of the seal width wsi of the web material 200 to the cell wide point Wei of the web material 200 is about 1 :5. In some embodiments, the cell wide point wci of the web material 200 is less than or equal to one or more of about 1.0 inches (2.54 cm), 0.9 inches (2.29 cm), 0.8 inches (2.03 cm), 0.7 inches (1.78 cm), 0.6 inches (1.52 cm), or 0.5 inches (1.27 cm). In one particular example, the cell wide point wci of the web material 200 is about 0.5 inches (1.27 cm) and the seal width wsi of the web material 200 is about 0.1 inches (0.254 cm).

[0054] Depicted in Figs. 4A and 4B are partial front and partial lower perspective views, respectively, of the web material 200 in an inflated state with a label 260 adhered thereon. In the depicted embodiment, the cell wide point wci of the web material 200 is about 0.5 inches (1.27 cm) and the seal width wsi of the web material 200 is about 0.1 inches (0.254 cm). The label 260 is adhered to portions of the tops of the inflated chambers 206. The entirety of the bottom side of the label 260 is not adhered to some portion of the web material 200. For example, as can be seen in Fig. 4B, gaps 262 exist between the label 260 and the web material 200 at the locations of the seals 230. Despite the existence of the gaps 262, respective sizes of the cell wide point wci of the web material 200 and the seal width wsi of the web material 200 cause the label 260 to be adhered to the web material 200 in a manner that the label 260 can be a shipping label. For example, the label 260 is adhered so that label 260 can serve as a shipping label on a package formed from the web material 200 for the duration of the shipping of the package. In some embodiments, the gaps 262 are sized and positioned so that the gaps 262 are unlikely to permit an object (e.g., a user’s finger, a protrusion on a conveyor belt at a shipping facility, a tool, etc.) from entering between the label 260 and the web material 200 to cause significant damage to the label 260 and/or to pull the label 260 off of the web material 200.

[0055] As noted above, seal patterns other than sinusoidal patterns (e.g., the sinusoidal pattern of the seals 230) can be used in web materials to form chambers that have cells and interconnecting channels. Non-sinusoidal seal patterns form chambers with cells that are not circular or ovoidal. The respective sizes of the cell wide point of a web material and the seal width of the web material allow a label to be adhered to the web material such that the label remains adhered to the web materials during shipping. Depicted in Figs. 5A and 5B are examples of web materials that have seals with non-sinusoidal seal patterns.

[0056] Fig. 5A depicts a partial front view of another embodiment of a web material 238 that includes a number of inflatable chambers 246. When viewing the depiction in Fig. 5A, the left and right sides of each of the chambers 246 are defined by seals 240. In the depicted embodiment, the seals 240 are nonlinear so that the chambers 246 formed by the seals 240 include cells 242 and interconnecting channels 244. In the depicted embedment, a pair of adjacent chambers 246 are offset so that the cells 242 of one of the chambers 246 are aligned with the interconnecting channels 244 of a subsequent one of the chambers 246. In some embodiments, a pair of adjacent chambers 246 are separated by only one of the seals 240.

[0057] In some embodiments, each of the seals 240 has a repeating pattern in the transverse direction (the vertical direction when viewing the depiction in Fig. 5A). In the depicted embodiment, the seals 240 have a four-segment line pattern that repeats. Adjacent ones of the seals 240 in the depicted embodiment have patterns that are mirrors of each other. In this way, the cells 242 are substantially octagonal in shape. In other embodiments, the seals 240 can have other types of patterns so that the cells 242 have a different shape.

[0058] Characteristics of the web material 238 can improve the adherability of labels to the web material 238 after inflation of the web material 238. In the depicted embodiment, the cells 242 have a cell wide point Wc2. In some embodiment, the cell wide point Wc2 is based on a distance between consecutive seals 240. Because the cells 242 in the depicted embodiment are substantially octagonal, the cell wide point Wc2 of the cells 242 can be defined as the distance between two sides of the octagonal shape. As is shown in the depicted embodiment, the cell wide point wc_å of the cells 242 can also be defined as the diameter of a circle inscribed inside of the octagonal shape of the cells 242. In other examples, the cell wide point wc_å of one of the chambers 246 can be defined as the widest point in the longitudinal direction (the horizontal direction when viewing the depiction in Fig. 5A) between the seals 240 in the chamber, the average width of some or all of the cells 242 in the chamber, or any other manner of determining a cell wide point wc_å of the cells 242 in the chamber. As can be seen in Fig. 5A, because pairs of adjacent chambers 246 are offset, the cell wide point Wc2 of the cells 242 in one of the chambers 246 may not be aligned with the cell wide point wc_å of the cells 242 of an adjacent one of the chambers 260. In some embodiments, the web material 238 may have a cell wide point that is defined as one or more of the largest cell wide point wc_å of any of the cells 242, an average cell wide point wc_å of all of the cells 242, an average cell wide point Wc2 of the chambers 246, or any variation thereof.

[0059] In the depicted embodiment, the seals 240 also have a seal width Ws2. In some embodiment, the seal width Ws2 is based on a distance between consecutive chambers 246. In the depicted embodiment, the seals 240 have a substantially uniform width and the seal width Ws2 is that substantially uniform width for each of the seals 240. In other embodiments, the width of an individual one of the seals 240 may vary between the port and the distal end of the chamber 246. In such a case, the seal width Ws2 of the seal 240 may be one or more of the average width of the seal 240, the minimum width of the seal 240, or the maximum width of the seal 240. In some embodiments, the web material 238 may have a seal width that is defined as one or more of the largest seal width Ws2 of any of the seals 240, an average seal width Ws2 of all of the seals 240, an average seal width Ws2 of the seals 240, or any variation thereof.

[0060] In some embodiments, the relative characteristics of the seal width Ws2 and to the cell wide point wc_å can influence the adherability of labels to the web material 238 after inflation of the web material 238. In some embodiments, a ratio of the seal width Ws2 of the web material 238 to the cell wide point wc_å of the web material 238 is in a range from about 1 :4 to about 1 :15. In some embodiments, a ratio of the seal width Ws2 of the web material 238 to the cell wide point wc_å of the web material 238 is in one of the following ranges: from about 1 :4 to about 1 :12, from about 1 :4 to about 1 :10, from about 1 :4 to about 1 :8, or from about 1 :4.5 to about 1 :6. In some embodiments, a ratio of the seal width Ws2 of the web material 238 to the cell wide point Wc2 of the web material 238 is about 1 :5. In some embodiments, the cell wide point Wc2 of the web material 238 is less than or equal to one or more of about 1.0 inches (2.54 cm), 0.9 inches (2.29 cm), 0.8 inches (2.03 cm), 0.7 inches (1.78 cm), 0.6 inches (1.52 cm), or 0.5 inches (1.27 cm). In one particular example, the cell wide point wc_å of the web material 238 is about 0.5 inches (1.27 cm) and the seal width Ws2 of the web material 238 is about 0.1 inches (0.254 cm).

[0061] Fig. 5B depicts a partial front view of another embodiment of a web material 248 that includes a number of inflatable chambers 256. When viewing the depiction in Fig. 5B, the left and right sides of each of the chambers 256 are defined by seals 250. In the depicted embodiment, the seals 250 are nonlinear so that the chambers 256 formed by the seals 250 include cells 252 and interconnecting channels 254. In the depicted embedment, a pair of adjacent chambers 256 are offset so that the cells 252 of one of the chambers 256 are aligned with the interconnecting channels 254 of a subsequent one of the chambers 256. In some embodiments, a pair of adjacent chambers 256 are separated by only one of the seals 250.

[0062] In some embodiments, each of the seals 250 has a repeating pattern in the transverse direction (the vertical direction when viewing the depiction in Fig. 5B). In the depicted embodiment, the seals 250 have a two-segment line pattern that repeats. Adjacent ones of the seals 250 in the depicted embodiment have patterns that are mirrors of each other. In this way, the cells 252 are substantially hexagonal in shape. In other embodiments, the seals 250 can have other types of patterns so that the cells 252 have a different shape.

[0063] Characteristics of the web material 248 can improve the adherability of labels to the web material 248 after inflation of the web material 248. In the depicted embodiment, the cells 252 have a cell wide point w_C3. In some embodiment, the cell wide point Wc3 is based on a distance between consecutive seals 250. Because the cells 252 in the depicted embodiment are substantially hexagonal, the cell wide point Wc3 of the cells 252 can be defined as the distance between two vertices of the hexagonal shape. As is shown in the depicted embodiment, the cell wide point Wc3 of the cells 252 can also be defined as the diameter of a circle circumscribed about the vertices of the hexagonal shape of the cells 252. In other examples, the cell wide point Wc3 of one of the chambers 256 can be defined as the widest point in the longitudinal direction (the horizontal direction when viewing the depiction in Fig. 5B) between the seals 250 in the chamber, the average width of some or all of the cells 252 in the chamber, or any other manner of determining a cell wide point Wc3 of the cells 252 in the chamber. As can be seen in Fig. 5B, because pairs of adjacent chambers 256 are offset, the cell wide point Wc3 of the cells 252 in one of the chambers 256 may not be aligned with the cell wide point Wc3 of the cells 252 of an adjacent one of the chambers 260. In some embodiments, the web material 248 may have a cell wide point that is defined as one or more of the largest cell wide point Wc3 of any of the cells 252, an average cell wide point Wc3 of all of the cells 252, an average cell wide point Wc3 of the chambers 256, or any variation thereof.

[0064] In the depicted embodiment, the seals 250 also have a seal width ws3. In some embodiment, the seal width Ws3 is based on a distance between consecutive chambers 256. In the depicted embodiment, the seals 250 have a substantially uniform width and the seal width Ws3 is that substantially uniform width for each of the seals 250. In other embodiments, the width of an individual one of the seals 250 may vary between the port and the distal end of the chamber 256. In such a case, the seal width Ws3 of the seal 250 may be one or more of the average width of the seal 250, the minimum width of the seal 250, or the maximum width of the seal 250. In some embodiments, the web material 248 may have a seal width that is defined as one or more of the largest seal width Ws3 of any of the seals 250, an average seal width Ws3 of all of the seals 250, an average seal width Ws3 of the seals 250, or any variation thereof.

[0065] In some embodiments, the relative characteristics of the seal width Ws3 and to the cell wide point Wc3 can influence the adherability of labels to the web material 248 after inflation of the web material 248. In some embodiments, a ratio of the seal width Ws3 of the web material 248 to the cell wide point Wc3 of the web material 248 is in a range from about 1 :4 to about 1 : 15. In some embodiments, a ratio of the seal width Ws3 of the web material 248 to the cell wide point wee of the web material 248 is in one of the following ranges: from about 1 :4 to about 1 :12, from about 1 :4 to about 1 :10, from about 1 :4 to about 1 :8, or from about 1 :4.5 to about 1 :6. In some embodiments, a ratio of the seal width Ws3 of the web material 248 to the cell wide point Wc3 of the web material 248 is about 1 :5. In some embodiments, the cell wide point Wc3 of the web material 248 is less than or equal to one or more of about 1.0 inches (2.54 cm), 0.9 inches (2.29 cm), 0.8 inches (2.03 cm), 0.7 inches (1.78 cm), 0.6 inches (1.52 cm), or 0.5 inches (1.27 cm). In one particular example, the cell wide point Wc3 of the web material 248 is about 0.5 inches (1.27 cm) and the seal width Ws3 of the web material 248 is about 0.1 inches (0.254 cm).

[0066] For purposes of this disclosure, terminology such as“upper,”“lower,”

“vertical,”“horizontal,”“inwardly,”“outwardly,”“inner,”“outer,”“front,”“rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of“including,”“comprising,” or“having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,”“coupled,” and“mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms“substantially,”“approximately,” and the like are used to mean within 5% of a target value.

[0067] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the

embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and

equivalents fall within the spirit and scope of the present disclosure, as claimed.

Claims

CLAIMS What is claimed is:

1. A web material, comprising:

two juxtaposed sheets arranged to form an inflatable web, wherein the inflatable web comprises two longitudinal edges and chambers located between the two longitudinal edges; and

seals between the two juxtaposed sheets that define sides of the chambers, wherein the seals have a pattern so that the chambers formed by the seals include cells and interconnecting channels;

wherein the web material has a cell wide point based on a distance between consecutive ones of the seals;

wherein the web material has a seal width based on a distance between consecutive ones of the seals; and

wherein a ratio of the seal width of the web material to the cell wide point of the web material is in a range from about 1 :4 to about 1 :15.

2. The web material of claim 1 , wherein the chambers extend across the web material in a transverse direction.

3. The web material of claim 2, wherein the chambers are arranged in a pattern that generally repeats in a longitudinal direction, and wherein the longitudinal direction is substantially perpendicular to the transverse direction.

4. The web material of claim 1 , wherein:

the chambers are arranged so that a first chamber and a second chamber are adjacent to each other; and

the first and second chambers are offset so that the cells in the first chamber are aligned with the interconnecting channels of the second chambers.

5. The web material of claim 1 , wherein the pattern of the seals is a sinusoidal pattern that repeats.

6. The web material of claim 5, wherein the sinusoidal pattern of the seals is configured such that adjacent ones of the seals are mirrors of each other and the cells in the chambers are circular or ovoidal in shape.

7. The web material of claim 1 , wherein the pattern of the seals is a line pattern that repeats.

8. The web material of claim 7, wherein the line pattern of the seals is configured such that adjacent ones of the seals are mirrors of each other and the cells in the chambers are polygonal in shape.

9. The web material of claim 1 , wherein the ratio of the seal width of the web material to the cell wide point of the web material is in one of the following ranges: from about 1 :4 to about 1 :12, from about 1 :4 to about 1 :10, from about 1 :4 to about 1 :8, or from about 1 :4.5 to about 1 :6.

10. The web material of claim 1 , wherein the ratio of the seal width of the web material to the cell wide point of the web material is about 1 :5.

1 1. The web material of claim 1 , wherein the cell wide point of the web material is less than or equal to one or more of about 1.0 inches, 0.9 inches, 0.8 inches, 0.7 inches, 0.6 inches, or 0.5 inches.

12. The web material of claim 1 , wherein the cell wide point of the web material is one or more of a largest cell wide point of any of the cells, an average cell wide point of all of the cells, or an average cell wide point of the chambers.

13. The web material of claim 1 , wherein the seal width of the web material is one or more of a largest seal width of any of the seals, an average seal width of the seals, or an average seal width of the seals.

14. A method comprising:

inflating chambers of a web material, wherein the web material comprises: two juxtaposed sheets arranged to form an inflatable web, wherein the inflatable web comprises two longitudinal edges, and wherein the chambers are located between the two longitudinal edges, and

seals between the two juxtaposed sheets that define sides of the chambers, wherein the seals have a pattern so that the chambers formed by the seals include cells and interconnecting channels,

wherein the web material has a cell wide point based on a distance between consecutive ones of the seals,

wherein the web material has a seal width based on a distance between consecutive ones of the seals, and

wherein a ratio of the seal width of the web material to the cell wide point of the web material is in a range from about 1 :4 to about 1 :15;

sealing closed the inflated chambers of the web material; and

adhering a label to an exterior side of portions of the cells of the chambers.

15. The method of claim 14, further comprising:

forming the web material into a pouch;

receiving an object into the pouch; and

closing the pouch to form a package of the web material with the object located therein.

16. The method of claim 15, wherein the pouch is closed to form the package either after or while the label is adhered to the exterior side of the portions of the cells of the chambers.

17. The method of claim 14, wherein, after the label is adhered to the exterior side of the portions of the cells of the chambers, one or more gaps exist between the label and the web material.

18. The method of claim 17, wherein the one or more gaps are at locations of one or more of the seals.