Fiber-based composite material for padded mailers and corresponding systems and methods are provided herein. A fiber-based composite includes a fiber-based backing material and a fiber-based padding attached to the backing material to provide cushioning for items within a mailer. The fiber-based padding is applied as a plurality of tubular structures, each defining a perimeter extending from a first point of attachment to a second point of attachment. The perimeter further defines an apex point which is spaced apart both laterally and vertically from a center point on the backing material that is between the first and second points of attachment. A plane connecting the center point and the apex point defines an angle with the backing material that is greater than 5 degrees and less than 75 degrees.

An inflator inflates inflatable webs. The inflator includes a web supply holding device that holds a supply of an inflatable web, a first gas moving device having a first inlet for receiving gas and a first outlet for expelling gas, a second gas moving device having a second inlet for receiving gas and a second outlet for expelling gas, and a nozzle. The first outlet is coupled to the second inlet such that gas expelled from the first outlet is received by the second inlet. The nozzle is coupled to the second outlet and inserts gas expelled from the second outlet into the inflatable web to inflate the inflatable web. Parameters of the first and second gas moving devices are selected based on a type of the inflatable web.

A system includes a supply of an inflatable web (100) and a nozzle (240). The inflatable web includes chambers (116), an inflation channel (112), and cross seals (114) between the inflation channel and the chambers. The inflatable web also includes ports (124) that pass through the cross seals to permit gas to pass from the inflation channel to the chambers. The nozzle has an outlet (242) configured to insert gas into the inflation channel as the inflatable web is moved in a downstream direction. The system is configured to feed the inflatable web along a path from the supply and past the nozzle in the downstream direction. The system is configured to hold the supply of the inflatable web with respect to the nozzle such that the cross seals contact the nozzle and rides along a portion of the nozzle as the inflatable web is moved in the downstream direction.

A method and system for forming domes or protruded structures in a flat material such as paper is disclosed. The method includes cutting one or more sheets; applying an adhesive between the one or more sheets, joining the one or more sheets together in a registered manner to form a substrate, encapsulating the one or more sheets in a container to prevent curing of the adhesive, opening the container, and pressing the adhesive under pressure to shape the substrate into a desired shape may include the domes or protruded structures.

A cushioning member includes: an accommodating bag portion that accommodates a medium; a first fusing portion that defines the accommodating bag portion such that the accommodating bag portion is provided with an opening; a check valve having a first end located inside the accommodating bag portion and a second end located outside the accommodating bag portion, and provided at the opening; a second fusing portion that is immediately adjacent to the first fusing portion on those external sides of the check valve which are opposite in a direction intersecting a direction in which the check valve protrudes from the accommodating bag portion, and defines a channel that communicates with the opening; and a third fusing portion that is connected to the second fusing portion and seals the channel, the third fusing portion being provided across a portion of the check valve that protrudes from the accommodating bag portion.

A packaging material includes a web of pouches and an outer skin. One panel of the web has an inflation pattern that is not inflated. The web has a continuous inflation channel that is in fluid communication with the inflation pattern. Each of the pouches of the web can be inflated by inflating the inflation pattern while the outer skin already attached to the outside of the web. The outer skin is attached to the web only along edge lines of the pouches. The outer skin is detached from the web between the edge lines of the pouches. The outer skin is attached to the outside of the web such that the continuous inflation pattern extends above the outer skin.

An inflatable web is disclosed. The web includes first and second film plies sealed together via a plurality of generally transverse seals to define a first and second inflatable chambers and an inflation region. The chambers are inflatable with a fluid and operable to contain the fluid. The sealed plies have a first longitudinal edge and a second longitudinal edge. The web defines a separation region extending at least partially transversely across the web between the first and second inflatable chambers and is configured to facilitate separation thereof. The separation region includes a tear propagation line extending transversely across at least a portion of the web with an end of the tear propagation line terminating proximal to the first longitudinal edge of the web. The separation region includes a tear initiation feature including edges spaced apart from one another longitudinally to form a permanent opening in the web.

A protective packaging web is disclosed. The web includes a flexible inflatable web that includes inflatable chambers having inlets and configured for receiving a fluid from the inlets and sealing the fluid therein, the inflatable chambers being configured such that, when inflated, the inflatable web structure has a first contoured exterior surface including a plurality of peaks and valleys, and a flexible first outer ply affixed to the peaks and detached from the valleys of the first contoured surface, such that when the inflatable chambers are inflated, the first outer ply extends along a phantom first tangential surface, bridging the valleys of the first contoured surface, such that when the chambers are inflated the affixed first outer ply and the inflatable web cooperatively form a framed structure having significantly elevated bending stiffness compared to a bending stiffness resulting from the inflatable web structure absent the attached first outer ply.

A method and system for forming domes or protruded structures in a flat material such as paper is disclosed. The method includes cutting one or more sheets; applying an adhesive between the one or more sheets, joining the one or more sheets together in a registered manner to form a substrate, encapsulating the one or more sheets in a container to prevent curing of the adhesive, opening the container, and pressing the adhesive under pressure to shape the substrate into a desired shape may include the domes or protruded structures.

A packaging apparatus with an improved pinch roller apparatus, fluid supply apparatus, and/or a sealing apparatus. The pinch roller apparatus (e.g., comprising one or more guide and/or pinch rollers) is used to deliver film material to the fluid supply apparatus (e.g., nozzle and blower apparatus, or the like) that fills one or more chambers of the film material with fluid (e.g., air, gas, or other like fluid), and the film material is then sealed by a sealing apparatus (e.g., using one or more heating elements with an improved temperature sensor configuration) that seals the fluid within the one or more chambers in order to form the inflated article (e.g., inflated packaging material). In particular, the sealing apparatus provides improved sealing through the improved accuracy of the temperature reading in the heating zone, in part, by locating a sensor between a heating element and a protective member that covers the sensor.