Method for forming air inflated cushioning material

A method affording on site inflation of cushioning material comprising:

• forming an elongate strip material comprising two thin flexible films, each film comprising a heat sealable thermoplastic material forming at least one surface of the film, by the steps of positioning the films with their thermoplastic surfaces adjacent and with their thermoplastic surfaces in face-to-face contact and fusing the films together in discrete areas to define a plurality of unsealed adjacent surface areas in a pattern providing two rows of inflatable chambers between the films and a passageway extending the length of the strip between the rows of chambers with each of the chambers having an inlet opening communicating with the passageway, the inlet opening to each of said chambers having a width in the longitudinal direction of the strip material is less than the width of the chamber in said direction;
• propelling the strip material along a strip path from an inlet end to an outlet end with a nozzle having an outlet end directed toward the inlet end of the strip path positioned in the passageway of the strip material;
• opening one of the films of the strip material along its passageway at a position spaced from the terminal end of the nozzle toward the outlet end of said strip path to afford movement of the strip material along the strip path;
• passing gas under pressure through the nozzle into the passageway;
• blocking the passageway within a predetermined distance from said nozzle toward the inlet end of the strip path to direct air in the passageway into the inlet openings of the chambers;
• applying heat to sequentially seal the inlet openings to the inflated chambers of the strip material along a predetermined sealing path longitudinal of the strip material;
• tensioning the strip material along the strip path during said applying step to remove wrinkles from the inlet openings;
• cooling the sealed inlet openings after said heat applying step;
• and
• pressing the films together along the sealing path and in an area on the side of the sealing path adjacent the row of chambers both during the applying step and during said cooling step.