A transfer and dispensing apparatus is disclosed for the conveying and separation of packaging material, cushions or pillows when needed by the operator. When a packer working over a conveyor receives a box that requires void fill, an operating switch such as a foot pedal is depressed to dispense pillows from the apparatus and into the box in a connected strip. When the operating switch is released, the apparatus stops dispensing pillows, separates the continuous strip of pillows along a transverse perforation in the strip, and ejects the end of the separated segment. The packer can then complete packing the box by placing the severed end of the pillows into the box, advance to the next box, and repeat the process. The transfer and dispensing apparatus may be positioned in any convenient location including adjacent to, above or attached to the inflation device.

Perforation tool for a device for the manufacturing by machine of a dunnage material which is to be formed of a single layer or multi-layer paper web whereby the perforation tool is configured for introducing a perforation into the dunnage material and comprises: at least one perforation nose, at least one perforation reception wherein the at least one perforation nose and the at least one perforation reception are associated with each other such that, for perforating, the at least one perforation nose can retract and extend with respect to the at least one perforation reception, and at least one stripper which is associated with the at least one perforation nose and/or the at least one perforation reception such that, when disengaging, perforated dunnage material is removed from the at least one perforation nose and/or from the at least one perforation reception.

An inflatable web is disclosed. The web includes a first film and second film ply sealed together via a plurality of generally transverse seals. The transverse seals define first and second inflatable chambers. The inflatable chambers are inflatable with, and contain, a fluid. The web defines a separation region extending at least partially between the first and second inflatable chambers in a substantially transverse direction across the web and configured to facilitate separation of the first and second inflatable chambers. The separation region includes a tear initiation feature that facilitates tearing of the web to separate the first and second inflatable chambers. The separation region includes a tear propagation line at least partially longitudinally offset from the tear initiation feature, and close enough to the tear initiation feature that force imparted to the web via the tear initiation feature will tear of the web through the tear propagation line.

In accordance with a broad embodiment of the invention, a novel paper product is comprised of two or more slit sheet packing material layers, each layer having its own slit pattern design to create interlocking layers of expansion sheet packaging materials. Each layer expands to create a three dimensional open netting of cells of hexagons, and the like, and is designed to have limited nesting with its opposing layer, thereby maximizing the thickness of the combined layers as compared to nested layers. Adjacent layers have differing slit patterns and can be expanded through expander type machinery such that the expansion rates of the differing slit pattern layers can be varied to deliver the same width of exiting expanded material from each layer. Preferably the differing slit pattern produce when expanded, inclined land areas that have the same number of rows per inch, but different angles of inclination of the land areas, such that adjacent layers can interlock, that is, have a restricted amount of nesting.

A preformed web and a method of producing dunnage units from the preformed web. The web is an elongate flattened thermoplastic tube having an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of perforations that allow adjacent dunnage units to be separated. A starting point of the lines of perforations is spaced apart from the inflation edge. The positions of the starting point of the lines of perforations with respect to the inflation edge is selected such that a cutter that cuts the inflation edge clears the line of perforations. Binding or wrinkling is therefore not caused by engagement of the cutter with the lines of perforations.

An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.

An inflatable web is disclosed. The web includes a first and second film ply sealed together. The transverse seals define first and second inflatable chambers. The web defines a separation region extending at least partially between the first and second inflatable chambers in a substantially transverse direction across the web and configured to facilitate separation of the first and second inflatable chambers. The separation region includes a tear initiation feature that facilitates tearing of the web to separate the inflatable chambers. The separation region includes a tear propagation line including a first plurality of perforations perforation is separated from an adjacent perforation by a land having a first transverse length. A tear initiation feature includes a second plurality of perforations, each perforation separated from an adjacent perforation by a land having a second transverse length, where the first transverse length is longer than the second transverse length.

An inflatable web is disclosed. The web includes a first film and second film ply sealed together via a plurality of generally transverse seals. The transverse seals define first and second inflatable chambers. The inflatable chambers are inflatable with, and contain, a fluid. The web defines a separation region extending at least partially between the first and second inflatable chambers in a substantially transverse direction across the web and configured to facilitate separation of the first and second inflatable chambers. The separation region includes a tear initiation feature that facilitates tearing of the web to separate the first and second inflatable chambers. The separation region includes a tear propagation line at least partially longitudinally offset from the tear initiation feature, and close enough to the tear initiation feature that force imparted to the web via the tear initiation feature will tear of the web through the tear propagation line.

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 formation device is disclosed herein. The device includes an inflation assembly that directs fluid between first and second overlapping plies of a web material. The device also includes a sealing mechanism. The sealing mechanism includes a heating zone and a cooling zone. The sealing mechanism also includes a heating element that extends along both the heating zone and the cooling zone, with the heating element having a first profile in the heating zone and a second profile in the cooling zone.