Apparatus for inflating and sealing pillows in packaging cushions

A system for manufacturing air cushions for use as packaging dunnage comprising:

• (a) a longitudinally extending plastic film comprising a relatively narrow longitudinally extending channel, at least one row of generally rectangular presealed inflatable chambers each having three sides closed and a fourth side with an unsealed opening into the longitudinally extending channel, and a plurality of laterally extending perforations separating the inflatable chambers, wherein the laterally extending perforations extend the entire width of the film;
• and
• (b) an inflation machine for inflating the inflatable chambers of the plastic film, the inflation machine comprising:
• an elongate member adapted for slidable insertion into the narrow longitudinally extending channel of the plastic film,
• a feed mechanism that causes the plastic film to be gripped at or near the narrow longitudinally extending channel and drawn in a continuous and uninterrupted manner through inflation, sealing and slitting mechanisms in a planar path,
• wherein the inflation mechanism comprises a source of inflation gas and an air outlet which together cause inflation gas to be injected into the inflation side of one or more of the inflatable chambers as the film is drawn through the inflation mechanism;
• wherein the sealing mechanism comprises an electrically energized heating element that generates heat to be delivered to the inflation side of one or more of the inflatable air chambers to seal the unsealed opening and trap the inflation gas within the chambers as the film is drawn through the sealing mechanism;
• and
• wherein the slitting mechanism comprising a blade that slices open the relatively narrow longitudinally extending channel of the plastic film to allow the film to disengage from the elongate member as the film is drawn through the slitting mechanism.