Reciprocating sealer for web converters

A method for forming sealed pouches from a linearly moving web using a plurality of seal cycles occurring while the web is continuously moving, where each of the sealed pouches includes corresponding sealed margins around product to contain and seal the product therein, the method comprising:

• moving the web along a linear web path passing between a first seal plate having a seal area and a second seal plate, wherein the seal area has a size for simultaneously forming all of the corresponding sealed margins for creating a set of at least one of the sealed pouches during each of the plurality of seal cycles, wherein the first and second seal plates are on opposing sides of the linearly moving web, wherein the seal area has a length in line with the web and a width extending across at least a majority of a width of the web, and wherein the length of the seal area is longer than the width of the sealed web;
• implementing a motion profile for providing the first seal plate and the second seal plate with reciprocating motion while the linearly moving web is continuously moving along the linear web path, the reciprocating motion being used to perform a sealing operation on the linearly moving web during each of the plurality of seal cycles to create the set of at least one of the sealed pouches, the reciprocating motion including a linear forward plate motion while the linearly moving web is continuously moving along the linear web path and a backward plate motion while the linearly moving web is continuously moving along the linear web path, the motion profile including, for each of the first and second seal plates, a first vector component substantially parallel with the linear web path to provide the linear forward plate motion substantially parallel with the linear web path at a velocity substantially equal to a velocity of the web, and a second vector component substantially perpendicular with the linear web path into contact with the web for the sealing operation while the web moves along the linear web path, wherein a linear rail aligned substantially parallel with the linear web path is used to guide the linear forward plate motion and the backward plate motion, wherein implementing the motion profile includes applying a first force guided using the linear rail to provide the first vector component and applying a second force to provide the second vector component, wherein the first and second seal plates are maintained substantially parallel to each other and to the linear web path when the first and second seal plates are moved into contact with the web;
• and
• simultaneously forming all of the sealed margins corresponding to the set of at least one of the sealed pouches to seal product therein during each of the plurality of seal cycles by applying a desired pressure between the first and second seal plates at the seal area throughout the sealing operation when the substantially parallel first and second seal plates are in contact with the web.