An exemplary air cushion inflation machine includes: a first terminal connected to a direct current input; a second terminal; a reference resistor powered by the direct current input; an op-amp; and a transistor. The first terminal of the op-amp is connected to a variable voltage source and the second terminal of the op-amp is connected to the reference resistor. The transistor has a base connected to an output of the op-amp, an emitter connected to the reference resistor, and a collector connected to a first terminal of a sealing band apparatus having first and second terminals. A meltable material placed between the first and second terminals is melted by resistance of current flowing between the first and second terminals. The variable voltage source changes voltage based on a voltage drop measured across the first and second terminals by a voltage measurement device and the constant current.

A bag for producing a foam-in-bag dunnage material comprises a closed edge portion and, in a non-sealed state of the bag, an open edge portion, the closed and open edge portions delimiting an inner bag volume. The invention proposes that a bag structure of the bag comprises a mixing chamber which is adapted to receive foam precursor substances, which is arranged within the inner bag volume, which is at least partially and initially delimited against the remainder of the inner bag volume, and which in the non-sealed state of the bag is connected to the open edge portion.

A protective packaging formation device is provided herein. The device includes an inflation assembly having a fluid conduit that directs fluid between overlapping plies of a polymeric web. The device also includes a driving mechanism that drives the film in a downstream direction. The device also includes a sealing mechanism that includes a thin film heater that heats the plies to create a longitudinal seal that seals the plies of film together. The driving mechanism drives the web such that the web slides across the heating assembly in a downstream direction to trap fluid between the plies.

A void-fill package, and method of making the same, comprising at least 50%, on a weight basis of the package, recycled polyethylene; at least 40%, on a weight basis of the package, virgin polyethylene; at least one moisture scavenger; and at least one melt stabilizer.

A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

A protective packaging formation device is provided herein. The device includes an inflation assembly having a fluid conduit that directs fluid between overlapping plies of a polymeric web. The device also includes a driving mechanism that drives the film in a downstream direction. The device also includes a sealing mechanism that includes a thin film heater that heats the plies to create a longitudinal seal that seals the plies of film together. The driving mechanism drives the web such that the web slides across the heating assembly in a downstream direction to trap fluid between the plies.

A machine for converting two different types of webs of inflatable material to two different types of inflated cushioning material includes an inflation arrangement, a sealing arrangement, and a tensioning device. The inflation arrangement is configured to provide air at a lower pressure to a first web of a first type of inflatable material to inflate the first type of inflatable material, and to provide air at a higher pressure to a second type of inflatable material to inflate the second type of inflatable material. The inflation arrangement includes a guide pin configured to the first and second webs and align the first and second webs on the machine. The sealing arrangement is configured to seal the first type of inflatable material and the second type of inflatable material to create the two different types of inflated cushioning material. The tensioning device is configured to provide a lower tensioning force to the first web as the first web moves between the inflation arrangement and the sealing arrangement, and to provide a higher tensioning force to the second web as the second web moves between the inflation arrangement and the sealing arrangement.

Inflatable structures, or aeromorphs, are provided with reinforcing member shape controlling features. The inflatable structure includes a bladder formed of a programmable substrate and defining an outer perimeter. The bladder includes a plurality of seams and a plurality of foldable segments defined by the plurality of seams. At least one hinge is provided, located adjacent each foldable segment. The hinge is configured to permit a folding movement of the respective foldable segment. At least one reinforcing member is provided, secured to the bladder and configured to guide a directional movement of at least one of the plurality of foldable segments, control a shape of the inflatable structure, and determine a sequence of folding. In various aspects, the reinforcing member includes a thermoplastic polyurethane, and is secured to a surface of the bladder with additive manufacturing techniques, such as 3-D printing.

A packing material including a plurality of discrete cushioning elements and methods for making the same. The discrete cushioning elements may be cellulosic cushioning elements. A flexible linkage may connect the plurality of discrete cushioning elements in the packing material. The packing material may also include a bottom cellulosic sheet connected to a top cellulosic sheet with the plurality of cellulosic cushioning elements positioned between the top cellulosic sheet and the bottom cellulosic sheet. The packing material may also be a molded packing material that includes bonds comprising adhesive and cellulosic fibers. The adhesive and cellulosic fibers of the bonds may be dispersed between the folds of each of the cellulosic cushioning elements.

A machine includes an inflation arrangement, a sealing arrangement, and a tensioning device. The inflation arrangement provides air at a first pressure to inflate a first web of a first type of inflatable material, provides air at a second pressure to inflate a second web of a second type of inflatable material, receives the first and second webs, and aligns the first and second webs on the machine. The first pressure is different from the second pressure. The sealing arrangement seals the first and second types of inflatable material. The tensioning device provides a first tensioning force to the first web as the first web moves between the inflation and sealing arrangements and provides a second tensioning force to the second web as the second web moves between the inflation and sealing arrangements. The first tensioning force is different from the second tensioning force.