阅读说明：本技术 张力引发型轴组件 (Tension-inducing axle assembly ) 是由 A·T·伍德 于 2020-02-17 设计创作，主要内容包括：一种张力引发型轴系统包括轴、两个轴盖和偏置机构。孔在所述轴的两个端部之间延伸穿过所述轴。所述轴盖定位在所述轴的所述两个端部上。每一轴盖包括具有大于所述孔的大小的的套环、键合端和锚固件。所述偏置机构布置在所述孔内部并且耦接到所述轴盖的所述锚固件,使得所述偏置机构在所述轴盖上施加向内力。所述轴盖的所述键合端可以耦接到壳体,使得所述轴盖并不相对于所述壳体旋转。所述轴被配置成相对于所述轴盖旋转,使得当所述键合端耦接到所述壳体时,所述轴能够相对于所述壳体旋转。(A tension inducing axle system includes an axle, two axle caps, and a biasing mechanism. A bore extends through the shaft between the two ends of the shaft. The shaft covers are positioned on the two ends of the shaft. Each shaft cap includes a collar having a size larger than the aperture, a bonding end, and an anchor. The biasing mechanism is disposed inside the bore and coupled to the anchor of the shaft cover such that the biasing mechanism exerts an inward force on the shaft cover. The bond end of the shaft cover may be coupled to a housing such that the shaft cover does not rotate relative to the housing. The shaft is configured to rotate relative to the shaft cover such that the shaft is rotatable relative to the housing when the bond end is coupled to the housing.)

1. A system, comprising:

a shaft having a first end and a second end, the shaft including a bore extending through the shaft from the first end to the second end;

a first shaft cover positioned on the first end of the shaft, wherein the first shaft cover includes a first collar having a size larger than the bore, a first bonding end, and a first anchor;

a second shaft cap positioned on the second end of the shaft, wherein the second shaft cap comprises a second collar having a size larger than the aperture, a second bond end, and a second anchor;

a biasing mechanism disposed inside the bore of the shaft and coupled to the first anchor of the first shaft cover and the second anchor of the second shaft cover such that the biasing mechanism exerts an inward force on the first shaft cover and second shaft cover;

wherein the first and second bond ends are configured to be coupled to a housing such that the first and second shaft covers do not rotate relative to the housing; and is

Wherein the shaft is configured to rotate relative to the first and second shaft caps such that the shaft is rotatable relative to the housing when the first and second bond ends are coupled to the housing.

2. The system of claim 1, wherein at least one of the first anchor and the second anchor is configured to swivel.

3. The system of claim 2, wherein the at least one of the first and second anchors is configured to gyrate during respective rotation of the first and second shaft caps such that the respective rotation of the first and second shaft caps does not induce a torque on the biasing mechanism or the first and second anchors sufficient to plastically deform the biasing mechanism or the first and second anchors.

4. The system of claim 1, wherein:

the first shaft cover further comprises a first body configured to slide from the first end of the shaft inside the bore of the shaft; and is

The second shaft cover further includes a second body configured to slide within the bore of the shaft from the second end of the shaft.

5. The system of claim 4, wherein:

the first anchor extends from an end of the first body of the first shaft cap; and is

The second anchor extends from an end of the second body of the second shaft cap.

6. The system of claim 4, further comprising:

a first counter bore at the first end of the shaft;

a second counter bore at the first end of the shaft;

a first bearing located in the first counterbore, wherein a coefficient of friction between the first bearing and the first body of the first shaft cap is less than a coefficient of friction between the bore and the first body of the first shaft cap; and

a second bearing located in the second counterbore, wherein a coefficient of friction between the second bearing and the second body of the first shaft cap is less than a coefficient of friction between the bore and the second body of the second shaft cap.

7. The system of claim 4, wherein the material of the first collar, the first body, the first collar, the second body, and the second collar comprises at least one of a self-lubricating plastic or a low friction plastic.

8. The system of claim 4, wherein the material of the first collar, the first body, the first collar, the second body, and the second collar comprises polyoxymethylene.

9. The system of claim 1, wherein the shaft includes a circumferential groove located near the first end of the shaft.

10. The system of claim 9, further comprising:

a clip located in the circumferential groove, wherein the clip is configured to act as a side alignment for at least one of a film roll positioned on the shaft or an end cap positioned on the shaft.

11. The system of claim 1, wherein the shaft includes at least one keyed surface.

12. The system of claim 11, wherein the at least one keyed surface is configured to key to a corresponding surface of at least one of a film roll positioned on the shaft or an end cap positioned on the shaft.

13. The system of claim 1, wherein:

the first bond end is a square or rectangular projection extending from the first collar of the first shaft cover; and is

The second bond end is a square or rectangular projection extending from the second collar of the second shaft cap.

14. A system, comprising:

a housing; and

a shaft assembly, the shaft assembly comprising:

a shaft having a first end and a second end, the shaft including a bore extending through the shaft from the first end to the second end,

a first shaft cover positioned on the first end of the shaft,

a second shaft cap positioned on the second end of the shaft, an

A biasing mechanism disposed inside the bore of the shaft and coupled to the first and second shaft caps such that the biasing mechanism exerts an inward force on the first and second shaft caps;

wherein the first and second shaft caps are coupled to the housing such that the first and second shaft caps do not rotate relative to the housing; and is

Wherein the shaft is configured to rotate relative to the first and second shaft caps such that the shaft is rotatable relative to the housing.

15. The system of claim 14, further comprising:

a film supply roll loaded on the shaft such that rotation of the film supply roll relative to the housing causes rotation of the shaft relative to the housing.

16. The system of claim 15, wherein the supply roll of film comprises film wound around a core, wherein retraction of the film from the core causes rotation of the supply roll.

17. The system of claim 16, further comprising:

a first end cap configured to be inserted into a first end of the core; and

a second end cap configured to be inserted into the second end of the core.

18. The system of claim 17, wherein each of the first and second end caps comprises an aperture that permits each of the respective first and second end caps to slide onto and across the shaft.

19. The system of claim 14, wherein:

the housing includes a first slot and a second slot;

the first shaft cover includes a first bond end;

the second shaft cover includes a second bond end; and is

The first and second shaft covers are configured to be coupled to the housing by sliding the first and second key ends into the first and second slots, respectively.

20. The system of claim 19, wherein the shaft assembly is configured to be decoupled from the housing by lifting the shaft assembly such that the first and second keyed ends of the first and second shaft covers slide out of the first and second slots, respectively.

21. The system of claim 14, wherein the shaft assembly is capable of holding supply rolls having a plurality of different widths.

Technical Field

The present disclosure is in the field of inflatable membranes. More particularly, the present disclosure relates to a tension inducing shaft that resists rotation of a roll of film to induce tension in the film as it is withdrawn from the roll.

Background

Air cellular cushioning materials are commonly used to protect items during shipment. One such product is rubber Wrap Air cushion sold by Sealed Air corporation. Air cellular cushions are typically prepared at a manufacturing facility and shipped in rolls to distributors and end users. Because the roll is bulky and has a large volume to weight ratio, shipping costs are relatively high. Additionally, the large volume to weight ratio means that a relatively large storage area may be required to store the inventory cushions.

To address these problems, inflatable membranes have been shipped to end users in supply rolls having a relatively low volume to weight ratio. The end user can inflate the membrane as desired. It is expected that the end user may utilize the following membrane inflation system: which reliably and consistently inflates such membranes and seals the membranes to provide the desired air cellular cushion.

Disclosure of Invention

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

In a first embodiment, a system includes a shaft, a first shaft cover, a second shaft cover, and a biasing mechanism. The shaft has a first end and a second end, and the shaft includes a bore extending through the shaft from the first end to the second end. The first shaft cover is positioned on the first end of the shaft. The first shaft cover includes a first collar having a size larger than the aperture, a first bond end, and a first anchor. The second shaft cover is positioned on the second end of the shaft. The second shaft cover includes a second collar having a size larger than the aperture, a second bond end, and a second anchor. The biasing mechanism is disposed inside the bore of the shaft and coupled to the first anchor of the first shaft cover and the second anchor of the second shaft cover such that the biasing mechanism exerts an inward force on the first and second shaft covers. The first and second bond ends are configured to be coupled to a housing such that the first and second shaft caps do not rotate relative to the housing. The shaft is configured to rotate relative to the first and second shaft caps such that the shaft is rotatable relative to the housing when the first and second bond ends are coupled to the housing.

In a second embodiment, at least one of the first anchor and the second anchor in the first embodiment is configured to swivel.

In a third embodiment, the at least one of the first and second anchors of the second embodiment is configured to gyrate during respective rotation of the first and second shaft caps such that the respective rotation of the first and second shaft caps does not induce a torque on the biasing mechanism or the first and second anchors sufficient to plastically deform the biasing mechanism or the first and second anchors.

In a fourth embodiment, the system of any of the preceding embodiment claims is configured such that the first shaft cover further comprises a first body configured to slide inside the bore of the shaft from the first end of the shaft, and the second shaft cover further comprises a second body configured to slide inside the bore of the shaft from the second end of the shaft.

In a fifth embodiment, the system of the fourth claim is configured such that the first anchor extends from an end of the first body of the first shaft cap and the second anchor extends from an end of the second body of the second shaft cap.

In a sixth embodiment, the system of any one of the fourth through fifth embodiments further comprises a first counterbore at the first end of the shaft, a second counterbore at the first end of the shaft, a first bearing in the first counterbore, and a second bearing in the second counterbore. A coefficient of friction between the first bearing and the first body of the first shaft cover is less than a coefficient of friction between the bore and the first body of the first shaft cover. A coefficient of friction between the second bearing and the second body of the first shaft cover is less than a coefficient of friction between the bore and the second body of the second shaft cover.

In a seventh embodiment, in the system of any one of the fourth to sixth embodiments, the material of the first collar, the first body, the first collar, the second body, and the second collar comprises at least one of a self-lubricating plastic or a low friction plastic.

In an eighth embodiment, in the system of any one of the fourth to seventh embodiments, the material of the first collar, the first body, the first collar, the second body, and the second collar comprises polyoxymethylene.

In a ninth embodiment, the system of any of the preceding embodiments, wherein the shaft comprises a circumferential groove located near the first end of the shaft.

In a tenth embodiment, the system of the ninth embodiment further comprises a clip located in the circumferential groove. The clip is configured to act as a side alignment (side alignment) of at least one of a film roll positioned on the shaft or an end cap positioned on the shaft.

In an eleventh embodiment, in the system of any of the preceding embodiments, the shaft includes at least one keyed surface.

In a twelfth embodiment, in the system of the eleventh embodiment, the at least one keyed surface is configured to be keyed to a corresponding surface of at least one of a film roll positioned on the shaft or an end cap positioned on the shaft.

In a thirteenth embodiment, in the system of any of the preceding embodiments, the first bond end is a square or rectangular projection extending from the first collar of the first shaft cap, and the second bond end is a square or rectangular projection extending from the second collar of the second shaft cap.

In a fourteenth embodiment, a system includes a housing and a shaft assembly. The shaft has a first end and a second end, and the shaft includes a bore extending through the shaft from the first end to the second end. The shaft also has a first shaft cover positioned on the first end of the shaft, a second shaft cover positioned on the second end of the shaft, and a biasing mechanism. The biasing mechanism is disposed inside the bore of the shaft and is coupled to the first shaft cover and the second shaft cover such that the biasing mechanism exerts an inward force on the first and second shaft covers. The first and second shaft covers are coupled to the housing such that the first and second shaft covers do not rotate relative to the housing. The shaft is configured to rotate relative to the first and second shaft caps such that the shaft is rotatable relative to the housing.

In a fifteenth embodiment, the system of the fourteenth embodiment further comprises a film supply roll loaded on the shaft such that rotation of the film supply roll relative to the housing causes rotation of the shaft relative to the housing.

In a sixteenth embodiment, the film supply roll of the fifteenth embodiment comprises film wound around a core, wherein retraction of the film from the core causes rotation of the supply roll.

In a seventeenth embodiment, the system of the sixteenth embodiment further comprises a first end cap configured to be inserted into the first end of the core, and a second end cap configured to be inserted into the second end of the core.

In an eighteenth embodiment, each of the first and second end caps of the seventeenth embodiment comprises an aperture that permits each of the respective first and second end caps to slide onto and across the shaft.

In a nineteenth embodiment, the system of any one of the fourteenth to eighteenth embodiments is configured such that the housing includes a first slot and a second slot, the first shaft cover includes a first keyed end, the second shaft cover includes a second keyed end, and the first and second shaft covers are configured to be coupled to the housing by sliding the first and second keyed ends into the first and second slots, respectively.

In a twentieth embodiment, the system of the nineteenth embodiment is configured such that the shaft assembly is configured to be decoupled from the housing by lifting the shaft assembly such that the first and second keyed ends of the first and second shaft covers slide out of the first and second slots, respectively.

In a twenty-first embodiment, the axle assembly of any one of the fourteenth to twentieth embodiments is capable of holding a supply roll having a plurality of different widths.

Drawings

The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when considered in connection with the accompanying drawings, wherein:

1A-1D depict perspective views of embodiments of membrane inflation systems according to embodiments disclosed herein;

FIG. 1E depicts a conceptual block diagram illustrating the relationship between various components and systems of the membrane inflation system depicted in FIGS. 1A-1D, according to embodiments disclosed herein;

FIG. 2A depicts an embodiment of a resistive sealer (dragsealer) configured to form a seal in a membrane after inflation of an inflatable channel in the membrane, according to embodiments disclosed herein;

FIG. 2B depicts a partial perspective view of the nozzle and roller assembly of the membrane inflation system depicted in FIGS. 1A-1D, according to embodiments disclosed herein;

fig. 2C is a perspective view of a resistance sealer positioned over a portion of a second roller according to embodiments disclosed herein;

fig. 3A and 3B depict bottom and side views, respectively, of a film moved by two rollers, inflated by a nozzle, and sealed by a resistive sealer, according to embodiments disclosed herein;

FIG. 4A depicts another embodiment of a nozzle, two rollers, and a resistive sealer according to embodiments disclosed herein;

FIG. 4B depicts another embodiment of a nozzle that may be used in conjunction with two rollers and a resistive sealer according to embodiments disclosed herein;

FIG. 5 depicts an embodiment of a film supply roll according to embodiments disclosed herein;

6A-6C depict partial cross-sectional views of the supply roll depicted in FIG. 5 with various alignments and misalignments of the film with the core of the supply roll according to embodiments disclosed herein;

fig. 7A and 7B depict an embodiment of an end cap configured to align with a film on a supply roll regardless of the alignment of the film on the core of the supply roll, according to embodiments disclosed herein;

fig. 8A and 8B illustrate examples of the end cap depicted in fig. 7A and 7B placed on a supply roll in both cases where the core and film are misaligned according to embodiments disclosed herein;

9A-9C depict perspective views of another embodiment of an end cap system according to embodiments disclosed herein;

10A-10B depict side views of embodiments of idlers configured to provide tension to film unwound from a supply roll in two different situations according to embodiments disclosed herein;

10C and 10D are another embodiment of a tensioning system configured to provide tension to a film unwound from a supply roll according to embodiments disclosed herein;

11A and 11B illustrate an example of how an idler pulley in the film inflation system illustrated in FIGS. 1A-1D maintains tension in a film according to embodiments disclosed herein;

12A-12F depict various views of one configuration of a membrane inflation system according to embodiments disclosed herein;

13A-13F illustrate various views of another configuration of the membrane inflation system illustrated in FIGS. 12A-12F, according to embodiments disclosed herein;

FIG. 14 depicts an embodiment of a membrane inflation system that may be used with a tension-inducing shaft according to embodiments disclosed herein;

fig. 15A depicts a perspective view of an embodiment of a shaft that may be used in a tension inducing shaft assembly according to embodiments disclosed herein;

fig. 15B depicts a perspective view of an embodiment of a tension inducing axle assembly including the axle shown in fig. 15A, according to embodiments disclosed herein;

16A and 16B depict front and rear perspective views, respectively, of an embodiment of a shaft cover included in the tension inducing shaft assembly shown in FIG. 15B, according to embodiments disclosed herein;

17A, 17B, and 17C depict a top view, a side view with partial cross-sectional view, and a bottom view, respectively, of one embodiment of a shaft cap that may be used in place of one or both of the shaft caps in the tension inducing shaft assembly shown in FIG. 15B, according to embodiments disclosed herein;

18A, 18B, and 18C depict a top view, a side view with partial cross-sectional view, and a bottom view, respectively, of another embodiment of a shaft cap that may be used in place of one or both of the shaft caps in the tension inducing shaft assembly shown in FIG. 15B, according to embodiments disclosed herein;

FIGS. 19A and 19B depict exploded and assembled side views, respectively, of the shaft assembly shown in FIG. 15B, according to embodiments disclosed herein;

FIGS. 19C and 19D depict exploded and assembled side views, respectively, of a shaft assembly that is a variation of the shaft assembly shown in FIG. 15B, according to embodiments disclosed herein;

FIG. 19E depicts a partial cross-sectional view of the shaft assembly shown in FIGS. 19C and 19D, according to embodiments disclosed herein; and is

Depicted in fig. 20A, 20B, 20C, and 20D are front views of the following cases, respectively, in accordance with embodiments disclosed herein: the axle assembly shown in fig. 15B, the axle assembly shown in fig. 15B holding an embodiment of a film supply roll, the axle assembly shown in fig. 15B holding the film supply roll in the film inflation system shown in fig. 14, and the axle assembly shown in fig. 15B holding another embodiment of a film supply roll in the film inflation system shown in fig. 14.

Detailed Description

The present disclosure describes embodiments of a membrane inflation system for inflating and sealing an inflatable membrane. In addition, the present disclosure describes various components of the film inflation system, including nozzles, sealers, idlers, and end caps for film supply rolls.

A nozzle in the membrane inflation system inflates an inflatable channel in the membrane. Some nozzle designs do not properly inflate the inflatable channels in the membrane. In some cases, the inconsistent inflation rate results in bubbles and air pillows being unusable in the package. Embodiments of nozzles that achieve proper inflation are described herein. In one example, a nozzle includes: a proximal end that opens both sides of the common membrane to open the common channel when the membrane moves in the membrane path direction; a distal end that permits both sides of the membrane to collapse as the membrane moves in a membrane path direction; and a slot configured to direct gas transversely into the common channel to inflate the inflatable channel when the membrane moves in the longitudinal direction. In some examples, the proximal end is curved, the distal end is tapered, and the slot is located in the tapered distal end.

A sealer in the membrane inflation system forms a seal in the membrane to seal the inflatable channel. Some sealer designs do not form a proper seal in the film. In some cases, the sealer forms a non-uniform seal in the inflatable material. Embodiments of a sealer that forms a proper seal in an inflatable membrane are described herein. In one example, a sealer has a body with a slot therein and a heating element exposed through a portion of the body. The film is moved by a roller assembly comprising a first roller and a second roller. One of the first and second rollers is a slotted roller and the slot in the body allows portions of a sealer to be located in the slotted roller such that a heating element is located between the first and second rollers. A heating element can be activated to cause a seal to be formed in the film as the film is moved by the first and second rollers.

Some film inflation systems, particularly those that pull the film from its sides, tend to form waves and creases in the film. In some cases, corrugations and creases are formed, which prevent the inflatable channel from being properly inflated. Embodiments of idlers that provide tension in the film to reduce the likelihood of forming ripples or creases in the film are described herein. In one example, the idler includes a bracket fixedly coupled to a housing of a film inflation system that holds a supply roll of film. An idler arm has a first end and a second end, and the first end of the idler arm is rotatably coupled to the bracket. A roller is rotatably coupled to the second end of the idler arm. A biasing mechanism biases the idler gear in the engaged position. When the idler is in the engaged position, the roller is in contact with the film supply roll, and the biasing mechanism causes the roller to exert a force on the film supply roll. In some examples, the biasing mechanism allows the idler pulley to switch between an engaged position and a retracted position in which the roller is not in contact with the supply roll.

The film supply roll provides film for the film inflation system to inflate and seal. In some cases, an extensive membrane path system moves the membrane and aligns the membrane with the inflation and sealing system. However, such a wide film path system can be expensive and require some skill of the operator to initially feed the film through the film path. Simpler membrane path systems typically do not properly align the membrane with the inflation and sealing system, resulting in poor inflation and/or sealing of the membrane. Embodiments of end caps that can be placed on a film supply roll to properly align the film with the film inflation system are described herein. In one example, an end cap includes an insert placed inside a core of a supply roll, a recessed portion coupled to the insert, and a flange coupled to the recessed portion and contacting a film on the supply roll. The end cap also includes a coupling mechanism on a side of the end cap opposite the supply roll. The coupling mechanism is in a fixed position relative to the flange and the coupling mechanism engages a coupling on a membrane inflation system. The recessed portion accommodates any portion of the core that extends beyond the film on the supply roll when the film is in contact with the flange.

Variations of the above-mentioned embodiments of the nozzle, sealer, idler, and end cap are described below. Those components are described below separately and in the context of a membrane inflation system. Additional components of the film supply system are also described below. The embodiments mentioned in the preceding paragraphs are only examples; it is not intended to identify key features of the claimed subject matter, nor to limit the scope of the claimed subject matter.

Fig. 1A-1D illustrate perspective views of an embodiment of a membrane inflation system 100. FIG. 1E depicts a conceptual block diagram showing the relationship between the various components and systems of the membrane inflation system 100. In the illustrated embodiment, the membrane inflation system 100 includes a housing 102 configured to house and/or couple to the components and systems of the membrane inflation system 100. In some embodiments, the housing 102 is made of a rigid material, such as aluminum, other metals, thermosets, rigid thermoplastics, and the like. In some embodiments, the housing 102 is of a size and shape that permits the membrane inflation system 100 to be used when placed on a book table top, placed on a table top, mounted on a wall, or any other consumer environment. In some embodiments, the housing 102 includes an outer structure configured to provide an exterior of the membrane inflation system 100 and/or an inner structure configured to provide support for the outer structure and the inner components of the membrane inflation system 100.

The membrane inflation system 100 includes a coupling 104 configured to permit a supply roll 130 of membrane 140 to be coupled to the membrane inflation system 100₁And 104₂(collectively coupling 104). In some embodiments, as will be discussed in more detail below, one or more of the couplings 104 are configured to releasably engage an end cap placed on an end of the supply roll 130 of film 140. In other embodiments, one or more couplings 104 are configured to releasably engage the supply roll 130 of film 140 itself. In the embodiments illustrated in FIGS. 1B-1D, the couplersConnecting piece 104₁Is configured to releasably engage a first coupling mechanism of the end cap (e.g., a groove in a mandrel of the end cap), and coupling 104₂A second coupling mechanism (e.g., a bond end of a mandrel) configured to receive an end cap. In the illustrated embodiment, coupling 104₂On a portion of the housing 102 that may be opposite the coupling 104 of the housing 102₁The portion at which it is located. Adjusting coupling 104₁And 104₂The ability to distance between allows the film inflation system 100 to accommodate film supply rolls of different widths.

In some embodiments, the membrane 140 is a two-layer membrane having a common channel in fluid communication with a plurality of inflatable channels. The inflatable channels are arranged to be inflated to have a three-dimensional cushion shape. When on the supply roll 130, the inflatable channels are deflated and the edges of the common channel are open. As will be discussed in more detail below, the membrane inflation system 100 is configured to move the membrane 140 along a membrane path during which the inflatable channels are inflated through the common channel and the inflatable channels are individually sealed.

In some embodiments, one or both sides of the membrane 140 include at least one or more of: polyethylene, ethylene/alpha-olefin copolymers, ethylene/unsaturated ester copolymers, ethylene/unsaturated acid copolymers, polypropylene, propylene/ethylene copolymers, polyethylene terephthalate, polyamides, polyvinylidene chloride, polyacrylonitrile, ethylene/vinyl alcohol (EVOH), or propylene/vinyl alcohol (PVOH). Examples of films are described in U.S. patent nos. 7,807,253, 7,507,311, 7,018,495, 7,223,461, 6,982,113, and 6,800,162, the contents of all of which are hereby incorporated by reference in their entirety.

The membrane inflation system 100 includes a tensioner 106 coupled to the housing 102. The tensioner 106 is located in the film path downstream of the supply roll 130 of film 140. In some embodiments, the tensioner 106 is configured to guide the film 140 along a film path and maintain a level of tension in the film as it travels along a portion of the film path. In some embodiments, the tensioner 106 includes one or more protrusions extending from a portion of the housing 102 such that the common channel of the membrane 140 is in contact with the tensioner 106.

In some embodiments, the membrane inflation system 100 further includes an idler 108. As discussed below with respect to the embodiment shown in fig. 10A-10B, idler 108 may be biased in a switching configuration that switches between an engaged position in which idler 108 is biased toward supply roll 130 of film 140 and a retracted position in which idler is biased away from supply roll 130 of film 140. When idler 108 is biased toward supply roll 130 of film 140, as shown in fig. 1B, idler 108 reduces the likelihood of corrugations and/or creases forming in film 140 as film 140 moves through the film path and as film 140 contracts during inflation. In some embodiments, the vertical and/or horizontal positioning of the idler 108 is selected to provide an amount of tension in the film that reduces the likelihood of forming ripples and/or creases during film deployment and channel inflation.

The membrane inflation system 100 also includes a nozzle 110. The nozzle 110 is configured to separate both sides of a common channel in the membrane 140 and insert gas through the common channel and into an inflatable channel in the membrane 140. In some embodiments, the nozzle 110 has a curved proximal end at a side of the nozzle 110 positioned upstream in the film path, a tapered distal end at a side of the nozzle 110 positioned downstream in the film path, and a longitudinal slot in the tapered distal end of the nozzle 110. The curved proximal end of the nozzle 110 is disposed on both sides of the common channel of the split membrane 140. The tapered distal end of the nozzle 110 is configured to permit the two sides of the membrane to converge before the membrane 140 is sealed. The longitudinal slots are configured to direct gas transversely into the inflatable channels of the membrane 140 as the membrane 140 moves along the membrane path.

Membrane inflation system 100 includes roller assembly 112. The roller assembly 112 is configured to drive the film 140 along a film path and seal the inflatable channel of the film 140. In the illustrated embodiment, the roller assembly 112 includes a first roller 114 and a second roller 116. The first roller 114 and the second roller 116 are positioned adjacent to each other or in an interference fit so that the first roller 114 and the second roller 116 contact each other. One side of the film 140 passes between the first roller 114 and the second roller 116. One or both of the first roller 114 and the second roller 116 are driven to pull the film 140 off the supply roll 130. In some embodiments, the film 140 is pulled by the first roller 114 and the second roller 116 at a rate up to a speed in the range of 9 to 12 feet per minute. In some embodiments, the first roller 114 and the second roller 116 are made of a resilient material, such as rubber or a resilient plastic.

Roller assembly 112 also includes a resistance seal 118. The resistance seal 118 is configured to form a seal in the membrane 140 after the inflatable channel in the membrane 140 is inflated. One embodiment of the resistive seal 118 is depicted in FIG. 2A. In the illustrated embodiment, the resistance seal includes a body 160 having a U-shape that includes a slot 162. In some embodiments, the body 160 is formed of one or more materials having a low thermal conductivity (i.e., less than or equal to about 10 Wm at a temperature of 20℃.)^-1K^-1) Such as one or more ceramic materials. The body 160 of the resistive seal 118 has a portion 164 through which the heating element 138 is exposed. In the illustrated embodiment, portion 164 is a flat portion over which membrane 140 may move. As the membrane 140 moves across the portion 164, the heating element 138 causes the two sides of the membrane 140 to seal to each other. The body 160 including the slot 162 is configured to be placed over a portion of a roller with the heating element 138 positioned substantially tangential to the roller.

The nozzle 110 and roller assembly 112 of the membrane inflation system 100 are shown in greater detail in the partial perspective view shown in FIG. 2B. In the depicted embodiment, the nozzle 110 has a curved proximal end 132 at a side of the nozzle 110 positioned upstream in the film path, a tapered distal end 136 at a side of the nozzle 110 positioned downstream in the film path, and a longitudinal slot 134 in the tapered distal end 136 of the nozzle 110. The curved proximal end 132 of the nozzle 110 is disposed on both sides of the common channel of the split membrane 140. In the depicted embodiment, the curved proximal end 132 has a hemispherical shape with a flat portion near the center of the hemispherical shape. The tapered distal end 136 of the nozzle 110 is configured to permit the two sides of the membrane 140 to converge before the membrane 140 is sealed. The longitudinal slot 134 is configured to direct gas transversely into the inflatable channel of the membrane 140 as the membrane 140 moves along the membrane path.

In the embodiment depicted in fig. 2B, the resistive seal 118 is located above a portion of the second roller 116. The slot 162 in the body 160 is configured to be positioned around the axle of the second roller 116. The heating element 138 is exposed on a portion 164 of the body 160 between the first roller 114 and the second roller 116. The heating element 138 is configured to heat the film 140 as the film 140 passes through the first roller 114 and the second roller 116 to seal both sides of the film 140 so that the individual channels are sealed after it is inflated. The first roller 114 and the second roller 116 exert pressure on the film 140 as the heating element 138 heats the film. The first roller 114 and the second roller 116 are configured to exert pressure on the film 140 as the film 140 is pulled through the first roller 114 and the second roller 116. Fig. 2C depicts a perspective view of the resistive seal 118 positioned over a portion of the second roller 116. As can be seen, the portion of the heating element 138 exposed on the portion 164 of the body 160 is arcuate in shape. In some embodiments (e.g., the embodiment shown in fig. 2C), the shape of the heating element 138 is based on the shape of the second roller 116. For example, the outer diameter of the heating element is substantially similar to the outer diameter of the second roller 116.

Returning to fig. 1A-1E, the membrane inflation system 100 also includes a gas source 120. In some embodiments, the gas source 120 comprises a gas compressor (e.g., an air compressor) or a container of pressurized gas. In the illustrated embodiment, the gas source 120 is located inside the housing 102. In other embodiments, the gas source 120 is located outside the housing 102. The gas source 120 is in fluid communication with the nozzle 110, and the gas source 120 is configured to supply a stream of gas to the nozzle 110 to inflate the inflatable channel in the membrane 140.

The membrane inflation system 100 also includes one or more motors 122 configured to drive one or both of the first roller 114 and the second roller 116. In some embodiments, the one or more motors 122 include one motor configured to drive one of the first roller 114 and the second roller 116, one motor configured to drive both the first roller 114 and the second roller 116, or two motors each configured to drive one of the first roller 114 and the second roller 116. In the illustrated embodiment, one or more motors 122 are located inside the housing 102. In other embodiments, the one or more motors 122 are located outside of the housing 102. In some embodiments, the one or more motors 122 include one or more of: an electric motor, a solenoid, a combustion engine, a pneumatic motor, a hydraulic motor, or any other type of rotary drive mechanism.

The membrane inflation system 100 also includes a controller 124. In some embodiments, the controller 124 includes one or more of the following: a Complex Programmable Logic Device (CPLD), a microprocessor, a multi-core processor, a co-processing entity, an application specific instruction set processor (ASIP), a microcontroller, an integrated circuit, an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), a Programmable Logic Array (PLA), a hardware accelerator, any other circuitry, or any combination thereof. A controller 124 is communicatively coupled to each of the resistance seal 118, the gas source 120, and the one or more motors 122. The controller 124 is configured to control the operation of the resistance sealer 118, such as whether the resistance sealer 118 is heating a heating element and/or the temperature of the heating element of the resistance sealer 118. In some embodiments, the controller 124 is configured to receive back information from the resistance seal 118, such as temperature sensor readings indicative of the temperature of the heating element of the resistance seal 118. The controller 124 is configured to control operation of the gas source 120, such as whether the gas source 120 is supplying gas to the nozzle 110 and/or the flow rate of gas from the gas source 120 to the nozzle 110. The controller 124 is configured to control the operation of the one or more motors 122, such as whether the one or more motors 122 are driving one or both of the rollers 114 and 116 and/or the rate at which the one or more motors 122 are driving one or both of the rollers 114 and 116.

The membrane inflation system 100 also includes a user interface 126. In some embodiments, user interface 126 includes physical buttons, a keyboard, a mouse, a touch screen display, a touch sensitive pad, a motion input device, a mobile input device, an audio input, a pointing device input, a joystick input, a keypad input, a peripheral device, an audio output device, a video output, a display device, a motion output device, a mobile output device, a printing device, a light (e.g., a Light Emitting Diode (LED)), any other input or output device, or any combination thereof. The user interface 126 is communicatively coupled to the controller 124. The user interface 126 is configured to receive user inputs, communicate user inputs to the controller 124, receive signals from the controller 124, and provide outputs to a user. In one example, the user interface 126 receives user inputs to begin moving and inflating the membrane, communicates signals indicative of the user inputs to the controller 124, receives an indication from the controller 124 that the membrane inflation system 100 is operating, and illuminates an LED to indicate that the membrane inflation system 100 is operating. Other functions that may be controlled via the user interface 126 include the flow rate of gas from the gas source 120 to the nozzle 110, the heat generated by the resistive seal 118, the operating speed of the one or more motors 122, or any other function of the membrane inflation system 100.

The membrane inflation system 100 also includes a power source 128. A power source 128 is coupled and configured to provide power to each of the resistive seal 118, the gas source 120, the one or more motors 122, the controller 124, and the user interface 126. In some embodiments, the power supply 128 includes a power adapter configured to receive AC power from an external source (e.g., an electrical outlet, a power source, etc.) and convert the AC power to an appropriate level and type of electrical power for each of the resistive seal 118, the gas source 120, the one or more motors 122, the controller 124, and the user interface 126. In other embodiments, the power source 128 includes one or more batteries (e.g., rechargeable batteries, DC batteries, etc.) configured to provide an appropriate level and type of electrical power to each of the resistive seal 118, the gas source 120, the one or more motors 122, the controller 124, and the user interface 126. In some embodiments, the controller 124 is configured to control electrical output from the power source 128 to one or more of the resistance seal 118, the gas source 120, the one or more motors 122, the controller 124, and the user interface 126. For example, the controller 124 may be configured to control the one or more motors 122 by controlling the amount of electrical power provided to each of the one or more motors 122 from the power source 128.

A bottom view of the film 140 moved by the first roller 114 and the second roller 116, inflated by the nozzle 110, and sealed by the resistive sealer 118 is shown in fig. 3A, respectively. The membrane 140 is formed of two layers of membrane forming a common channel 142 and an inflatable channel 144. A side view of the first and second rollers 114, 116 and the sealer 118, and a side view of the path of the edge 146 of the film 140 are shown in fig. 3B. For ease of viewing, the only portion of the membrane 140 depicted in FIG. 3B is the edge 146 of the membrane 140. The common channel 142 is in fluid communication with each of the inflatable channels 144 such that gas directed into the common channel by the nozzle 110 inflates the inflatable channels 144. In some embodiments, the two-ply membrane 140 is formed by folding a single membrane in half such that the ends of the membrane opposite the fold form the edges 146 of the common channel 142.

The first roller 114 and the second roller 116 are configured to move the film 140 in a direction 150 of the film path. The common channel 142 and edge 146 of the film pass between the first roller 114 and the second roller 116 such that rotation of the first roller 114 and the second roller 116 causes the film 140 to move in the direction 150. As the membrane 140 moves in the direction 150, the longitudinal slots 134 of the nozzle 110 will direct gas through the common channel 142 into each of the inflatable channels 144. The resistive seal 118 then forms a seal 148 in the film 140 as the film continues between the first roller 114 and the second roller 116. Seals 148 individually seal the inflatable channels to maintain the inflatable channels 144 in an inflated state. Thus, the inflatable channel 144 begins as a deflated inflatable channel 152 on the right side of fig. 3A and then becomes an inflated inflatable channel 154 after it is inflated and/or sealed on the left side of fig. 3A. Fig. 3A also depicts the inflatable channel 156 partially inflated in the middle of being inflated by the gas inserted by the nozzle 110.

The path of the edges 146 on both sides of the common channel 142 is shown in FIG. 3B. On the upstream side of direction 150 (on the right side of 3B), edges 146 of common channels 142 are slightly spaced apart. As the membrane 140 moves in the direction 150 and approaches the nozzle 110, the curved proximal end 132 of the nozzle 110 causes the edges 146 to separate to open the common channel 142. As the membrane 140 continues to move along the nozzle 110 in the direction 150, the body retaining edge 146 of the nozzle 110 between the curved proximal end 132 and the tapered distal end 136 separates.

As the membrane 140 continues to move further along the tapered distal end 136 in the direction 150, the tapered distal end 136 permits the edges 146 to approach one another. In the depicted embodiment, the longitudinal slot 134 is located in a tapered distal end 136 of the nozzle 110. The positioning of the longitudinal slot 134 in the tapered distal end 136 allows the inflatable channel 144 of the film 140 to be inflated just prior to the edges 146 of the film 140 gathering and continuing to travel between the first roller 114 and the second roller 116. This arrangement allows gas to remain in the inflatable channel 144 until the inflatable channel 144 is held closed by the first and second rollers 114, 116 and/or a seal 148 is formed by the resistive sealer.

Since the inflatable channel 144 allows gas to exit until it remains closed or sealed, it would be advantageous for the longitudinal slot 134 to be as close as possible to the first and second rollers 114, 116 and/or the heating element 138 of the resistive sealer 118. For ease of viewing, the nozzle 110 is positioned in fig. 3A and 3B relatively far from the first and second rollers 114, 116 and from the resistive seal 118. In other embodiments, the nozzle 110 is closer to the first roller 114 and the second roller 116 and away from the resistive seal 118. Another embodiment of the nozzle 110, first and second rollers 114, 116, and resistive seal 118 is illustrated in fig. 4A, where the nozzle 110 is in a different position relative to the first and second rollers 114, 116 and resistive seal 118. As shown in fig. 4A, the tapered distal end 136 is located adjacent to the first roller 114 and the second roller 116. In the depicted embodiment, the longitudinal slot 134 is located between the first roller 114 and the second roller 116 (e.g., the longitudinal slot 134 does not extend horizontally to the right as far as the first roller 114 and the second roller 116 extend to the right). In the depicted embodiment, the tapered distal end 136 of the nozzle 110 is located between the first and second rollers 114, 116 (e.g., the tapered distal end 136 does not extend horizontally to the right as far as the first and second rollers 114, 116 extend to the right). In the embodiment shown in fig. 4A, the first roller 114 and the second roller 116 are positioned in interference with each other.

Another embodiment of a nozzle 110' that may be used in conjunction with the first and second rollers 114, 116 and the resistive seal 118 is depicted in fig. 4B. The nozzle 110 'has a proximal end 132' at a side of the nozzle 110 'positioned upstream in the film path, a tapered distal end 136' at a side of the nozzle 110 'positioned downstream in the film path, and an outlet 134' located in the tapered distal end 136 'of the nozzle 110'. The proximal end 132 'of the nozzle 110' is configured to separate both sides of the common passageway of the membrane. In the depicted embodiment, the proximal end 132' has a wedge shape. The tapered distal end 136 'of the nozzle 110' is configured to permit the two sides of the membrane to converge before the membrane is sealed. The outlet 134' is configured to direct gas laterally into the inflatable channel of the membrane as the membrane moves along the membrane path.

An embodiment of a supply roll 200 is depicted in FIG. 5. The supply roll 200 includes a core 202. In some embodiments, the core 202 is made of a paper product (e.g., cardboard tube, kraft paper tube, etc.), a plastic material, or any other material. The supply roll 200 also includes a film 204 wound around the core 202. In some embodiments, the membrane 204 includes at least one or more of: polyethylene, ethylene/alpha-olefin copolymer, ethylene/unsaturated ester copolymer, ethylene/unsaturated acid copolymer, polypropylene, propylene/ethylene copolymer, polyethylene terephthalate, polyamide, polyvinylidene chloride, polyacrylonitrile, EVOH, or PVOH. In the depicted embodiment, the core 202 has a hollow bore 206. In some embodiments, the material and/or thickness of the core 202 is selected such that the core 202 is not deformed by the weight of the film 204 when the core 202 is placed on a mandrel or in other uses of the core 202.

One of the difficulties of film supply rolls is illustrated in fig. 6A-6C. A partial cross-sectional view of the supply roll 200 is shown in fig. 6A-6C. In the embodiment shown in fig. 6A, the ends of the core 202 are aligned with the ends of the membrane 204. In some cases (such as the case depicted in fig. 6B), the ends of the core 202 extend further out than the ends of the membrane 204. In other cases (such as that depicted in fig. 6C), the ends of the membrane 204 extend further out than the ends of the core 202. Although alignment of the core 202 and the membrane 204 (as depicted in fig. 6A) may be desirable in some cases, misalignment of the core 202 and the membrane 204 (as depicted in fig. 6B and 6C) may be common in most cases where it is impractical to align the core 202 and the membrane 204.

Misalignment of the core 202 and the membrane 204 may not allow for end-to-surface alignment of the membrane 204. In some examples, the hollow bore 206 may be placed over an axle having flanges on the sides. The supply roll 200 may be slid over the axle until a portion of the supply roll 200 contacts the flange. When the core 202 is aligned with the membrane 204 (e.g., in fig. 2A), the core 202 and membrane 204 will contact the flange. When the core 202 extends further than the membrane 204 (e.g., in fig. 2B), the core 202 will contact the flange, but the membrane 204 will be offset from the flange. When the membrane 204 extends further out than the core 202 (e.g., in fig. 2C), the membrane 204 will contact the flange, but the core 202 will be offset from the flange. Thus, the position of the membrane 204 relative to the flange varies based on the alignment or misalignment of the membrane 204 relative to the core 202.

One difficulty with not aligning the edge of the film 204 with the surface is that when the film 204 is misaligned, the film 204 may not be fed properly through the film path. Using the example of film inflation system 100, when film 140 is taken off supply roll 130, a change in the horizontal position of the side of film 140 may cause roller assembly 112 to improperly engage film 140. This may result in rippling of the membrane 140, poor inflation of the inflatable channels in the membrane 140, improper sealing of the inflatable channels in the membrane 140, and/or other defects.

An embodiment of an end cap 210 configured to be aligned to the film 204 on the supply roll 200 regardless of the alignment of the film 204 on the core 202 is depicted in fig. 7A and 7B. The end cap 210 includes a mandrel 212 configured to be inserted through the hollow bore 206 of the core 202. The end cap 210 also includes an insert 214 having an engagement element 216. The insert 214 is configured to be inserted into the hollow bore 206 of the core 202 such that the engagement element 216 engages an inner surface of the hollow bore 206. The end cap 210 has a recessed portion 218 extending from the insert 214 and a flange 220 extending from the recessed portion 218. In the axial direction (i.e., the direction parallel to the axis of the mandrel 212), the recessed portion 218 is recessed further away from the insert 214 than the extent to which the flange 220 is recessed away from the insert 214.

The mandrel 212 is configuredOne or more couplings configured to releasably couple to the membrane inflation system. The mandrel 212 includes a keyed end 222 opposite the end of the mandrel 212 with the flange 220. In some embodiments, the bond end 222 is configured to engage and releasably couple to a coupling of a membrane inflation system. For example, bond end 222 depicted in fig. 7A and 7B is configured to engage and releasably couple to coupling 104 of membrane inflation system 100₂. The mandrel 212 also includes a coupling mechanism 224 near an end of the mandrel 212 on the opposite side of the flange 220 from the supply roll 200. In some embodiments, the coupling mechanism 224 is configured to engage and releasably couple to a coupling of a membrane inflation system. In the embodiment depicted in fig. 7A and 7B, coupling mechanism 224 is configured to engage and releasably couple to coupling 104 of membrane inflation system 100₁The groove of (2).

Fig. 7A and 7B also illustrate an embodiment of an end cap 230 configured to be used on supply roll 200 in conjunction with end cap 210. The end cap 230 includes an insert 232 configured to be inserted into the hollow bore 206 of the core 202 and engage an inner surface of the hollow bore 206. The end cap 230 also has a flange 234 configured to contact one or more of the core 202 or the membrane 204. The end cap 230 also has a bore 236 configured to receive the mandrel 212. End cap 230 is configured to be placed on the end of supply roll 200 opposite the end of supply roll 200 where end cap 210 is placed.

Examples of end caps 210 and 230 placed on the supply roll 200 in both cases where the core 202 and film 204 are misaligned are shown in fig. 8A and 8B. In both fig. 8A and 8B, the end cap 210 is coupled to the left side of the supply roll 200 and the end cap 230 is coupled to the right side of the supply roll 200. The inserts 214 and 232 are located inside the hollow bore 206. The mandrel 212 of the end cap 210 passes through the aperture 236 of the end cap 230. When the coupling mechanism 224 and the bond end 222 are engaged to a coupling (e.g., coupling 104)₁And 104₂) At this time, the supply roll 200 can be rotated about the mandrel 212 to unwind the film 204 from the core 202.

In fig. 8A, the core 202 is misaligned with the film 204, where the film 204 extends further to the left than the core 202 on the left side of the supply roll 200. In this example, the end cap 210 has been slid to the right until the flange 220 contacts the left side of the membrane 204. The end cap 230 on the right side of the supply roll 200 has been slid to the left until the flange 234 comes into contact with the right side of the core 202. In this position, the mandrel 212 passes through the hole 236 in the end cap 230 with the bond end 222 extending out to the right of the end cap 230.

In fig. 8B, the core 202 is misaligned with the film 204, wherein the core 202 extends further to the left than the film 204 on the left side of the supply roll 200. In this example, the end cap 210 has been slid to the right until the flange 220 contacts the left side of the membrane 204. Even if the core 202 extends to the left of the left side of the membrane 204, the recessed portion 218 of the end cap 210 can accommodate the portion of the core 202 that extends beyond the left side of the membrane 204. The end cap 230 on the right end of the supply roll 200 has been slid to the left until the flange 234 comes into contact with the right side of the film 204. In this position, the mandrel 212 passes through the hole 236 in the end cap 230 with the bond end 222 extending out to the right of the end cap 230.

In both cases shown in fig. 8A and 8B, the flange 220 is in contact with the left side of the membrane 204. Since the flange 220 is in contact with the left side of the membrane 204 in both cases, the left side of the membrane 204 is approximately the same distance from the coupling mechanism 224 in the mandrel 212. Thus, when the coupling mechanism 224 engages a coupling (e.g., coupling 104)₁) When so, the left side of membrane 204 is approximately the same distance from the coupling, regardless of whether membrane 204 extends beyond core 202 (e.g., in fig. 8A) or vice versa (e.g., in fig. 8B). Although the coupling mechanism 224 is a groove that enables the spindle 212 to couple to a coupling, the coupling mechanism 224 may include any other type of coupling mechanism, such as a keyed portion, a slot, a clip, a pin, a bracket, and so forth.

A perspective view of another embodiment of an end cap system 500 is shown in fig. 9A-9C. The end cap system 500 includes a mandrel 510, a first end cap 520, and a second end cap 530. In the illustrated embodiment, the mandrel 510 is D-shaped with a cylindrical portion 512 and a planar section 514. As will be described in greater detail below, the D-shape of the mandrel 510 prevents relative rotation of the mandrel 510 with respect to either of the first end caps 520 and 530. This arrangement allows for controlled rolling friction of the membrane during deployment from the membrane core into which the first end caps 520 and 530 have been inserted. The mandrel 510 also includes first and second engagement members 516, 518 on opposite ends of the mandrel 510. The first and second engagement members 516 and 518 are configured to engage corresponding structural elements, such as a hanger or an aperture in a housing (e.g., housing 102), to permit rotational movement of a film roll mounted on the end cap system 500 relative to the housing.

The first end cap 520 includes a plug 522 configured to be inserted into one end of the roll core. The plug 522 includes a ridge 524 that is arranged to axially align with the roll core when the plug 522 is inserted into the roll core. The ridges 524 are configured to prevent relative rotation of the film core roll with respect to the first end cap 520. The first end cap 520 also includes a flange 526. When the plug 522 is inserted into the film roll core, one or both of the film and the film roll core contact the flange 526, depending on whether the film is aligned with the end of the film roll core (see, e.g., fig. 6A), the film roll core extends beyond the film (see, e.g., fig. 6B), or the film overhangs the end of the film roll core (see, e.g., fig. 6C). The first end cap 520 also includes a hole 528 arranged for insertion of the mandrel 520 therethrough. In the depicted embodiment, the hole 528 has a D-shape corresponding to the D-shape of the mandrel 520. When the mandrel 510 is inserted into the aperture 528 of the first end cap 520, the shape of the aperture 528 prevents relative movement of the mandrel 510 with respect to the first end cap 520.

The second end cap 530 includes a plug 532 configured to be inserted into the other end of the film roll core. The plug 532 includes ridges 534 arranged to axially align with the roll core when the plug 532 is inserted into the roll core. The ridges 534 are configured to prevent relative rotation of the film core roll with respect to the second end cap 530. The second end cap 530 also includes a flange 536. When the plug 532 is inserted into the film roll core, one or both of the film and the film roll core contact the flange 536 depending on whether the film is aligned with the end of the film roll core (see, e.g., fig. 6A), the film roll core extends beyond the film (see, e.g., fig. 6B), or the film overhangs the end of the film roll core (see, e.g., fig. 6C). The second end cap 530 also includes a bore 538 arranged for insertion of the mandrel 510 therethrough. In the depicted embodiment, the aperture 538 has a D-shape, corresponding to the D-shape of the mandrel 520. When the mandrel 510 is inserted into the bore 538 of the second end cap 530, the shape of the bore 528 prevents relative movement of the mandrel 510 with respect to the second end cap 530.

The end cap system 500 also includes an adjustable clamp 540. The adjustable clamp 540 is configured to be releasably secured to the mandrel 510. The adjustable clamp 540 may be released, moved axially along the mandrel 510 to a different position along the mandrel, and clamped again to secure the adjustable clamp 540 at a different position along the mandrel 510. The adjustable clamp 540 acts as a stop to prevent further translation of the first end cap 520 along the mandrel 520 in the axial direction. The ability to move and selectively secure the adjustable clamp 540 to the mandrel 510 allows the first end cap 520 to rest at different positions along the mandrel 520. To the extent that the ends of the film vary relative to the roll core (see, e.g., fig. 6A-6C), the user can select the position of the adjustable clamp 540 on the mandrel 510 such that when the end cap system 500 is placed on the housing, the edge of the film on the roll of film is a predetermined distance from the housing regardless of the position of the edge of the film relative to the roll core.

Although aligning one side of the film with the roller and sealer components of the film inflation system increases the ability of the film inflation system to properly inflate the film and seal the film. However, feeding the membrane from one side of the membrane also has some disadvantages. In some cases, pulling the film from one side may cause ripples and/or creases to form in the film as it exits the supply roll. The corrugations and/or folds may cause the inflatable channels in the membrane to be completely or partially blocked so that it is not fully inflated. Corrugations and/or creases in the film may also cause the film to become misaligned before it reaches the rollers and sealer components of the film inflation system, resulting in an incorrect sealing position in the film.

Fig. 10A and 10B depict side views of an embodiment of an idler 320 configured to provide tension to a film 304 unwound from a supply roll 300 in two different situations. The supply roll 300 includes a core 302 around which a film 304 is wound. The core 302 includes a hollow bore 306. Although not shown in fig. 10A and 10B, the supply roll 300 is removably coupled to the housing 308 of the membrane inflation system. In some examples, the end cap is placed on a side of the supply roll 300 and the end cap is configured to engage a coupling fixedly coupled to the housing 308. Housing 308 is configured to be placed on surface 310 and/or secured to surface 310. In some embodiments, surface 310 is one of the following: a floor, a desk top, a table, a wall, or any other type of surface.

Idler 320 includes a bracket 322 configured to be fixedly coupled to housing 308. In some embodiments, the bracket 322 is fixedly coupled to the housing 308 by one or more fasteners (e.g., bolts, nuts, screws, rivets, anchors, etc.). In some embodiments, the bracket 322 is fixedly coupled to the housing 308 by something other than fasteners (e.g., adhesives, welds, etc.). A first end of idler arm 324 is rotatably coupled to bracket 322 and a second end of idler arm 324 is rotatably coupled to roller 326. Idler arm 324 is configured to rotate about a first end of idler arm 324 relative to bracket 322. Roller 326 is configured to rotate relative to idler arm 324 about a second end of idler arm 324.

The idler 320 includes a biasing mechanism 328 configured to bias the idler arm 324 toward the supply roll 300. The biasing mechanism 328 causes the roller 326 to contact and apply a force to the film 304 on the supply roll 300. In the embodiment illustrated in fig. 10A and 10B, the biasing mechanism 328 is a tension spring coupled to the bracket 322 and to the second end of the idler arm 324. In other embodiments, the biasing mechanism 328 may be a compression spring, a torsion spring, a leaf spring, or any other type of biasing mechanism. In some embodiments, the biasing mechanism 328 is configured to permit the idler arm 324 to switch between an engaged position and a retracted position, as described in more detail below.

In the depiction shown in fig. 10A, idler 320 is in the engaged position. In this position, the force of the biasing mechanism 328 causes the roller 326 to contact the film 304 on the supply roll 300. As can be seen in fig. 10A, the film may be directed across the top of roller 326 and then to the left of idler 320. The film may then be pulled, for example, by a roller assembly (e.g., roller assembly 112 of film inflation system 100). As the roller assembly pulls the film 304, the biasing mechanism 328 resists any rotation of the idler arm 324 away from the supply roll 300. This resistance of biasing mechanism 328 results in tension in membrane 304 downstream of idler 320. This tension in the film 304 downstream of the idler 320, along with the position of the idler 320, reduces the likelihood of ripples and creases forming in the film 304.

In the depiction shown in fig. 9B, the idler 320 transitions from an engaged position (shown in phantom) to a retracted position (shown in solid). As the film 304 unwinds from the supply roll 300, the outer diameter of the film 304 decreases. As the outer diameter of the film 304 decreases, the biasing mechanism 328 causes the idler arm 324 to rotate such that the roller 326 continues to remain in contact with the film 304. As shown in phantom in fig. 9B, the idler 320 in the engaged position remains in contact with the membrane 304 even though the outer diameter of the membrane in fig. 9B is smaller than that of fig. 10A.

When the amount of film 304 on the supply roll 300 is low or exhausted, the supply roll 300 may be replaced with another supply roll. It may be advantageous to move the idler 320 to the retracted position such that the idler 320 does not interfere with the removal of the supply roll 300 from the housing 308 or the placement of another supply roll on the housing 308. To transition the supply roll 300 from the engaged position to the retracted position, the user may rotate the idler 320 in the direction indicated by the dashed arrow. In certain embodiments, when idler 320 is in the retracted position, roller 326 is in contact with surface 310. Additionally, in the depicted embodiment, biasing mechanism 328 biases roller 326 toward surface 310. In this manner, the idler 320 is switched to the engaged or retracted position to provide ease of use to the user.

An example of how idler 108 maintains tension in membrane 140 in membrane inflation system 100 is illustrated in fig. 10A and 10B. In fig. 10A, film 140 is fed from supply roll 130 over idler 108 and tensioner 106. From this point, the film 140 is fed into the first roller 114 and the second roller 116. Once the film is fed into the first and second rollers 114, 116, the first and second rollers 114, 116 may be driven to advance the film 140 further to the position shown in fig. 10B. Idler 108 reduces the likelihood of creases or waves forming in film 140 as film 140 is advanced by first roller 114 and second roller 116.

The amount of tension in film 140 may be affected by many characteristics of idler 108Influence. In some embodiments, one or more characteristics of idler 108 are selected based on a particular amount of tension in film 140 during operation of film inflation system 100. In some embodiments, the one or more characteristics of the idler 108 include one or more of: idler gear 108 at coupling 104₁And coupling 104₂A lateral position therebetween, a length of an idler arm of the idler 108, a height of a roller of the idler 108, a size (e.g., radius, width, etc.) of a roller of the idler 108, a strength of a biasing mechanism of the idler 108, or any other characteristic of the idler 108.

Another embodiment of a tensioning system 600 is shown in fig. 10C and 10D. The tensioning system 600 includes two tensioner components 602 and 604 extending from the housing 102'. In some embodiments, the tensioner members 602 and 604 extend a distance from the housing 102' such that the tensioner members 602 and 604 engage a portion of the lateral width of the film. In some embodiments, the tensioner members 602 and 604 extend a distance from the housing 102' such that the tensioner members 602 and 604 engage less than or equal to about half of the transverse width of the film. In some embodiments, the tensioner members 602 and 604 extend a distance from the housing 102' such that the tensioner members 602 and 604 engage less than or equal to about half of the transverse width of the film. In some embodiments, the tensioner members 602 and 604 extend a distance from the housing 102' such that the tensioner members 602 and 604 engage less than or equal to about one-quarter of the transverse width of the film. In some embodiments, the tensioner members 602 and 604 extend a distance from the housing 102' such that the tensioner members 602 and 604 engage less than or equal to about at least one of the following percentages of the transverse width of the film: 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15% or 10%.

Also depicted in fig. 10C and 10D is a desired film path 606 for the film through the tensioning system 600. As shown, the film path extends from a roll of film mounted on end cap system 500 to below tensioner member 602. From there, the film path 606 travels up the left side of the tensioner member 602 and then between the tensioner members 602 and 604. From there, the film path 606 travels up the right side of the tensioner component 604. From there, the film path 606 travels around the top of the tensioner member 604 and is then pulled towards the nozzle 110'. In the depicted embodiment, the tensioner members 602 and 604 are positioned such that a portion of the film path 606 causes the film to move closer to the film roll as it passes through the tensioner members 602 and 604. In other words, when considering fig. 10D, the film moves to the left as it approaches tensioner assembly 602, the film moves to the right as it passes tensioner assemblies 602 and 604, and the film again moves to the left between tensioner assembly 604 and nozzle 110'. As the membrane path 606 passes between the tensioner components 602 and 604, the membrane moves to the right. This rightward movement can provide a certain level of tension in the film so that the film is properly inflated by the nozzle 110' and sealed by the resistive sealer 118 as it passes through the rollers 114 and 116. Embodiments of the tensioning system 600 may be used with or without additional tensioning devices (e.g., with or without idler 320).

The various embodiments of the membrane inflation system described herein may have a variety of forms and designs. Various views of one configuration of the membrane inflation system 400 are shown in fig. 12A-12F. In particular, fig. 12A shows a perspective view thereof; FIG. 12B shows a top view thereof; FIG. 12C shows a front view thereof; FIG. 12D shows a rear view thereof; FIG. 12E shows a left side view thereof; and fig. 12F shows a right side view thereof. Various views of another configuration of the membrane inflation system 400 are shown in fig. 13A-13F. In particular, fig. 13A shows a perspective view thereof; FIG. 13B shows a top view thereof; FIG. 13C shows a front view thereof; FIG. 13D shows a rear view thereof; FIG. 13E depicts a left side view thereof; and fig. 13F shows a right side view thereof.

As can be seen, the film inflation system 400 is configured to transition between two configurations to accommodate supply rolls of different widths. In the embodiment shown in fig. 12A-12F, the film inflation system 400 is configured to hold a long supply roll of film. In this configuration, the film inflation system also includes an idler pulley to help the tensioner maintain tension in the film as it passes through the film inflation system 400. In the embodiment shown in fig. 13A-13F, the film inflation system 400 is configured to hold a short supply roll of film. In this configuration, the idler has been removed. The idler pulley may be removed when there is insufficient space between the end of the tensioner and the end of the housing, or when the tensioner alone provides sufficient tension in the film as it passes through the film inflation system 400. When the membrane inflation system 400 is transitioned from the configuration shown in fig. 13A-13F back to the configuration shown in fig. 12A-12F, the idler may be placed back onto the housing.

In some embodiments, the shaft assembly holding the film roll is capable of inducing tension in the film as it is unwound from the film roll. Such a tension inducing axle assembly may provide a simple and cost-effective way of inducing tension in a film fed from a roll. An embodiment of a membrane inflation system 700 that may be used with a tension-inducing shaft is depicted in FIG. 14. The membrane inflation system 700 includes a housing 702 configured to house and/or couple to the components and systems of the membrane inflation system 700. In some embodiments, the housing 702 is made of a rigid material, such as aluminum, other metals, thermosets, rigid thermoplastics, and the like. In some embodiments, the housing 702 is of a size and shape that permits the membrane inflation system 100 to be used when placed on a book table top, placed on a table top, mounted on a wall, or any other consumer environment. In some embodiments, the housing 702 includes an outer structure configured to provide an exterior of the membrane inflation system 700 and/or an inner structure configured to provide support for the outer structure and the inner components of the membrane inflation system 700.

Membrane inflation system 700 also includes roller assembly 712. Roller assembly 712 is configured to drive the film along the film path and seal the inflatable channel of the film. In some embodiments, roller assembly 712 includes two rollers positioned adjacent to each other or in an interference fit. One side of the film may pass between rollers 116 and one or both of the rollers may be driven to pull the film off the supply roll. In some embodiments, the roller is made of a resilient material, such as rubber or resilient plastic. Roller assembly 712 may further include a resistive sealer (or other sealer) configured to form a seal in the membrane after inflation of the inflatable channel in the membrane.

The membrane inflation system 700 also includes a user interface 726. In some embodiments, user interface 726 includes physical buttons, a keyboard, a mouse, a touch screen display, a touch sensitive pad, a motion input device, a mobile input device, an audio input, a pointing device input, a joystick input, a keypad input, a peripheral device, an audio output device, a video output, a display device, a motion output device, a mobile output device, a printing device, a light (e.g., a Light Emitting Diode (LED)), any other input or output device, or any combination thereof. The user interface 726 may be communicatively coupled to the controller. The user interface 726 is configured to receive user input, communicate user input to the controller, receive signals from the controller, and provide output to a user. In one example, the user interface 726 receives user input to begin moving and inflating the membrane, communicates signals indicative of the user input to the controller, receives an indication from the controller that the membrane inflation system 700 is operating, and illuminates an LED to indicate that the membrane inflation system 700 is operating. Other functions that may be controlled via the user interface 726 include the flow rate of gas from the gas source to the nozzles, the heat generated by the resistive sealer, the operating speed of the roller motor, or any other function of the membrane inflation system 700.

The housing 702 of the membrane inflation system 700 includes slots 740 and 742 configured to couple to the ends of the shaft. In some embodiments, the shaft between slots 740 and 742 is configured to hold a roll of film that can be inflated and sealed by film inflation system 700. In the depicted embodiment, slots 740 and 742 include linear portions that are at non-parallel and non-perpendicular angles with respect to vertical. These linear portions may allow the ends of the shaft to slide into the correct position under the weight of the film roll and allow the shaft to slide back from slots 740 and 742 to replace the film roll. The slots 740 and 742 may be arranged such that the ends of the shaft may be slid into place in the slots 740 and 742, and the shaft may be manually slid out of the slots 740 and 742 without the use of tools.

A perspective view of an embodiment of a shaft 800 that may be used in a tension inducing type shaft assembly is depicted in fig. 15A. In the depicted embodiment, the shaft 800 has a substantially cylindrical shape extending from a first end 802 to a second end 804. The shaft 800 includes a bore 806 extending through the shaft 800 from the first end 802 to the second end 804. In some embodiments, shaft 800 has an outer diameter of about 1 inch and bore 806 has a diameter of about 0.5 inch. In some embodiments, the shaft 800 is made of one or more of: aluminum, steel, any other metal, or any alloy thereof. In some embodiments, the shaft 800 is made of a non-metallic material (e.g., a rigid plastic material, etc.).

In the illustrated embodiment, the shaft 800 includes a bonding surface 808 and a bonding surface 810. Bonding surfaces 808 and 810 are configured to bond to corresponding surfaces of a roll of film, an end cap holding a roll of film, or any other component. In other embodiments, the shaft 800 may include only one of the bonding surfaces 808 and 810. In still other embodiments, either of bonding surfaces 808 and 810 may not be included. The shaft 800 also includes a circumferential groove 812. In the depicted embodiment, the circumferential groove 812 is located near the first end 802 of the shaft 800.

A perspective view of an embodiment of a tension inducing axle assembly 820 including the axle 800 is depicted in fig. 15B. The shaft assembly 820 also includes a shaft cover 822 on the first end 802 of the shaft 800 and a shaft cover 824 on the second end 804 of the shaft 800. In the depicted embodiment, the shaft caps 822 and 824 are in the form of plugs, and a portion of each of the shaft caps 822 and 824 is located inside the bore 806 of the shaft 800. The shaft 800 is configured to rotate relative to each of the shaft covers 822 and 824. Shaft assembly 820 also includes a clip 825. The clip 825 is sized to be located in the circumferential groove 812. The clips 825 are configured to act as side registers for the film roll and/or end caps that hold the film roll.

Fig. 16A and 16B show front and rear perspective views, respectively, of an embodiment of a shaft cover 822. The shaft cover 822 includes a body 826, a collar 828, and a bond end 830. The body 826 is configured to slide inside the bore 806. In some embodiments, the cross-sectional shape (e.g., circular) of the body is similar to the cross-sectional shape (e.g., circular) of the hole 806. When the shaft cover 822 is in the position shown in fig. 15B, the body 826 is located inside the bore 806 proximate the first end 802. The collar 828 has a size larger than the aperture 806. The collar 828 is configured to contact the first end 802 of the shaft 800 and prevent the shaft cover 822 from entering the bore 806 beyond the position shown in fig. 15B. The bond end 830 is configured to engage a housing of a membrane inflation system such that the shaft cover 822 does not rotate relative to the housing. In the depicted embodiment, the bond ends 830 are in the form of squares or rectangles protruding from the collar 828. The square or rectangular bonding end 830 of the depicted embodiment is configured to engage the slot 740 in the housing 702 of the film inflation system 700 such that the shaft cover 822 does not rotate relative to the housing 702.

Shaft cover 822 also includes an anchor 832 located on the end of body 826. As discussed in more detail below, the anchors 832 are configured to couple the shaft cover 822 to a biasing mechanism (e.g., a spring). In the illustrated embodiment, the anchor 832 includes an aperture 834 through which a portion of the biasing mechanism can be inserted. For example, in the case where the biasing mechanism is a spring having a hook, the hook of the spring may be inserted through the aperture 834 to couple the spring to the shaft cover 822.

In the depicted embodiment, the anchors 832 are configured to swivel, such as by rotating relative to the body 826. In some embodiments, the body 826, the collar 828, and the bond tip 830 are made of one material (e.g., plastic) and the anchor 832 is made of another material (e.g., metal). In some embodiments, the body 826, collar 828, and bond tip 830 are made of a self-lubricating plastic and/or a low friction plastic, such as polyoxymethylene (sometimes sold under the trade name DELRIN by e.i. du point de Nemours and Company). In some embodiments, the shaft cover 824 may be identical to the shaft cover 822 shown in fig. 16A and 16B. In other embodiments, the shaft cap 824 may have a body, collar and bond tip that have the same shape and size as the body 826, collar 828 and bond tip 830. The shaft cap 824 may also have a non-rotating anchor extending from the body of the shaft cap 824. In yet another embodiment, the shaft cap 824 may have a swivel anchor and the shaft cap 822 may have a non-swivel anchor. In other words, in some embodiments, at least one of the anchors on the shaft caps 822 and 824 swivel, and possibly both of the anchors on the shaft caps 822 and 824 swivel.

17A, 17B, and 17C depict a top view, a side view with partial cross-sectional view, and a bottom view, respectively, of one embodiment of a shaft cover 840 that may be used in place of one or both of shaft covers 822 and 824. Shaft cover 840 includes a body 842, a collar 844, and a bond end 846, which are similar to body 826, collar 828, and bond end 830 of shaft cover 822. Shaft cover 840 also includes an anchor 848 extending from body 842. In the depicted embodiment, the anchor 848 includes an aperture 850 through which a portion of the biasing mechanism may be inserted. Portion 852 of anchor 848 is located inside body 842. A portion 852 of the anchor 848 inside the body 842 is configured to permit rotation of the anchor 848 relative to the body 842 while preventing linear movement of the anchor 848 relative to the body 842.

18A, 18B, and 18C depict a top view, a side view with partial cross-sectional view, and a bottom view, respectively, of one embodiment of a shaft cover 840' that may be used in place of one or both of shaft covers 822 and 824. The shaft cover 840' is a variation of the shaft cover 840. Shaft cover 840' includes a body 842, a collar 844, and a keyed end 846 that are identical to the corresponding elements of shaft cover 840. Shaft cover 840' includes an aperture 854 through a keyed end 846, collar 844, and a portion of body 842. Shaft cap 840' further includes anchor 856, which is a bolt-type anchor. Anchors 856 extend from body 842. In the illustrated embodiment, the anchor 848 includes an aperture 858 through which a portion of the biasing mechanism may be inserted. The anchor 856 also includes a head 860, which may be similar to a bolt head. The head 860 is configured such that the head may pass through the aperture 854 and be positioned within the aperture 854. The anchor 856 can be positioned as shown in fig. 18B by: the anchor 856 is inserted into the hole from the left side of the bonding end 830 (as shown in fig. 18B), and then the anchor 856 is passed right through the hole 854 until the head 860 reaches the end of the hole 854. The head 860 of the anchor 856 is configured to permit rotation of the anchor 856 relative to the body 842 while preventing rightward linear movement of the anchor 848 relative to the body 842 in the view shown in fig. 18B.

Fig. 19A and 19B show an exploded side view and an assembled side view, respectively, of the shaft assembly 820. In fig. 19A and 19B, cross-sectional views of shaft 800 and clip 825 are shown to facilitate viewing of other portions of shaft assembly 820. Shaft covers 822 and 824 and biasing mechanism 836 are also shown in full side view. In the illustrated embodiment, the shaft cover 824 has the same features as the shaft cover 822 illustrated in fig. 16A and 16B, including a body 826, a collar 828, a bond end 830, and an anchor 832 that pivots relative to the body 826. In the illustrated embodiment, the biasing mechanism 836 is a tension spring having a metal coil with hook portions on both sides. In other embodiments, the biasing mechanism 836 may be an elastic band or any other biasing mechanism configured to exert a substantially constant compressive force on the shaft caps 822 and 824.

As seen in fig. 19A, the shaft 800, shaft caps 822 and 824, clip 825, and biasing mechanism 836 may all be axially aligned with one another. According to the exploded view in fig. 19A, the shaft assembly 820 may be assembled into the configuration shown in fig. 19B. More specifically, the shaft assembly 820 may be assembled by: positioning the clip 825 in the groove 812, coupling the hook portion of the biasing mechanism 836 to the anchor 832 of the shaft covers 822 and 824, with the biasing mechanism 836 inside the bore 806, positioning the shaft cover 822 with the collar 828 against the first end 802 of the shaft 800 and positioning the body 826 in the bore 806, and positioning the shaft cover 824 with the collar 828 against the second end 804 of the shaft 800 and positioning the body 826 in the bore 806. The biasing mechanism 836 exerts an inward force 862 on the shaft cover 822 to cause the shaft cover 822 to engage the shaft 800 at the first end 802, and exerts an inward force 864 on the shaft cover 824 to cause the shaft cover 824 to engage the shaft 800 at the second end 804. In embodiments where the biasing mechanism 836 is a constant force biasing mechanism (e.g., a constant force tension spring), the inward forces 862 and 864 may be constant known forces. In some embodiments, the magnitude of inward force 862 is substantially similar to the magnitude of inward force 864.

Each of the shaft caps 822 and 824 is configured to rotate relative to the other of the shaft caps 822 and 824. One reason for one or both of the anchors to be a swivel anchor is to permit relative rotation of shaft caps 822 and 824 while biasing mechanism 836 is coupled to the anchor without inducing a torque on biasing mechanism 836 or the anchor sufficient to plastically deform biasing mechanism 836 or the anchor.

Each of the shaft covers 822 and 824 is configured to rotate relative to the shaft 800. When the keyed ends 830 of the shaft covers 822 and 824 are coupled to a housing (e.g., the housing 702) such that the shaft covers 822 and 824 do not rotate relative to the housing, the shaft 800 can still rotate relative to the housing by rotating relative to the shaft covers 822 and 824. When a roll of film is loaded onto the spindle 800 and the film is unwound from the roll, the spindle 800 will rotate relative to the spindle covers 822 and 824. The friction between the shaft 800 and the shaft covers 822 and 824 will resist rotation of the roll, resulting in tension in the film being unwound from the roll. In embodiments where the force exerted by the biasing mechanism 836 is substantially constant, the frictional force between the shaft 800 and the shaft caps 822 and 824 is also substantially constant. In this manner, the tension induced in the membrane by the shaft assembly 820 may be substantially constant.

An exploded side view and an assembled side view of an embodiment of the shaft assembly 820' are shown in fig. 19C and 19D, respectively. FIG. 19E illustrates a partial cross-sectional view of the shaft assembly 820' shown in FIG. 19C. Shaft assembly 820' is similar to shaft assembly 820 with some exceptions. Shaft assembly 820 'includes shaft 800'. Shaft 800' is similar to shaft 800 in that it includes a first end 802, a second end 804, a bore 806, and other features. The shaft 800' also includes a counter bore 870 at the first end 802 of the shaft 800. The counter bore 870 has a larger diameter than the hole 806. Shaft 800' includes bearings 872 located in counterbores 870. The coefficient of friction between the bearing 872 and the body 826 of the shaft cover 822 is lower than the coefficient of friction between the bore 806 and the body 826 of the shaft cover 822. The shaft 800' also includes a counter bore 874 at the second end 804 of the shaft 800. The counter bore 874 has a larger diameter than the hole 806. The shaft 800' includes a bearing 876 that is seated in a counter bore 874. The coefficient of friction between the bearing 876 and the body 826 of the shaft cover 824 is lower than the coefficient of friction between the bore 806 and the body 826 of the shaft cover 824. Shaft assembly 820' operates similar to the operation of shaft assembly 820 described herein.

As described above, the shaft assembly 820 may be used to hold a film supply roll in a film inflation system to induce tension in the film as it is fed from the roll to the film inflation system. Fig. 20A, 20B, 20C, and 20D are front views respectively showing the following cases: the shaft assembly 820, the shaft assembly 820 holds an embodiment of the film supply roll, the shaft assembly 820 holds the film supply roll in the film inflation system 700, and the shaft assembly 820 holds another embodiment of the film supply roll in the film inflation system 700. In fig. 20B, 20C and 20D, the film supply roll is shown in cross-sectional view through a plane that is generally vertical and passes through the axis of the shaft 800. In fig. 20C and 20D, the housing 702 of the membrane inflation system 700 is shown in cross-sectional view through the same plane that is generally vertical and passes through the axis of the shaft 800.

In fig. 20A, the shaft assembly 820 has been assembled. A shaft cover 822 is on the first end 802 of the shaft 800 and a shaft cover 824 is on the second end 804 of the shaft 800. Although not visible in fig. 20A, a biasing mechanism 836 passes through the aperture 806 and is coupled to each of the first and second shaft caps 822 and 824. The biasing mechanism 836 causes an inward force to be exerted on each of the first and second shaft caps 822 and 824. The shaft 800 is rotatable relative to each of the first and second shaft caps 822 and 824. In the depicted embodiment, the shaft 800 has been rotated such that the bonding surface 808 is oriented at the front of the shaft assembly 820. The clip 825 is located in the recess 812 of the shaft 800 proximate the first end 802 of the shaft 800.

In fig. 20B, a supply roll 882 of film 884 has been loaded onto shaft assembly 820. Supply roll 882 includes a core 886. In some embodiments, the core 886 is made of a paper product (e.g., cardboard tube, kraft paper tube, etc.), a plastic material, or any other material. In the supply roll 882, the film 884 is wound around a core 886. In some embodiments, the film 884 includes at least one or more of: polyethylene, ethylene/alpha-olefin copolymer, ethylene/unsaturated ester copolymer, ethylene/unsaturated acid copolymer, polypropylene, propylene/ethylene copolymer, polyethylene terephthalate, polyamide, polyvinylidene chloride, polyacrylonitrile, EVOH, or PVOH. In the depicted embodiment, the core 886 has a hollow bore.

Supply roll 882 has been loaded onto end caps 888 and 890. The end cap 888 is configured to be inserted into one end of the hollow bore of the core 886 and the end cap 890 is configured to be inserted into the other end of the hollow bore of the core 886. In some embodiments, the material and/or thickness of the core 886 is selected such that the core 886 is not deformed by the weight of the membrane 884 when the core 886 is placed over the end caps 888 and 890. In some embodiments, the end caps 888 and 890 are made of a rigid material, such as a rigid plastic material, a metallic material, or the like.

End caps 888 and 890 may be placed on supply roll 882 prior to supply roll 882 and end caps 888 and 890 being loaded onto supply roll 882. After end caps 888 and 890 are placed on supply roll 882, supply roll 882 and end caps 888 and 890 may be slid onto shaft 800. In the depicted embodiment, the end cap 888 may be slid onto the right end of the shaft 800 (as viewed in fig. 20B), the end cap 888 may be slid leftward until the end cap 890 is also slid onto the right end of the shaft 800, and then the end caps 888 and 890 may be slid further leftward until the end cap 888 contacts the clip 825, and the supply roll 882 and the end caps 888 and 890 are in the position shown in fig. 20C. Each of the end caps 888 and 890 has an aperture that permits the end caps 888 and 890 to slide onto the shaft 800 and across the shaft 800. In some embodiments, the apertures in end caps 888 and 890 have a shape corresponding to a cross-section of shaft 800. For example, in the depicted embodiment, the apertures in end caps 888 and 890 may have surfaces that correspond to keyed surfaces 808. In this manner, the end caps 888 and 890 are keyed to the shaft 800 such that rotation of the shaft 800 causes corresponding rotation of the end caps 888 and 890, and vice versa.

With supply roll 882 and end caps 888 and 890 loaded onto shaft assembly 820, shaft assembly 820 may be placed into housing 702 of membrane inflation system 700. In some embodiments, the shaft assembly 820 is placed into the housing 702 of the membrane inflation system 700 by: the keyed ends 830 of the shaft covers 822 and 824 are slid through the slots 740 and 742, respectively, until the shaft assembly 820 is in the position depicted in fig. 20C. In the illustrated position, the bonding end 830 and the slots 740 and 742 are shaped to prevent rotation of the shaft covers 822 and 824 relative to the housing 702.

With the shaft assembly 820 placed into the housing 702 of the film inflation system 700, the film 884 can be withdrawn from the supply roll 882 to supply the film 884 to the film inflation assembly. For example, film 884 may be fed from supply roll 882 to roller assembly 712, and roller assembly 712 may feed film 884. When the membrane 884 is retracted from the supply roll 882, the retraction of the membrane 884 will cause the supply roll 882 to rotate relative to the housing 702. Rotation of the supply roll 882 causes corresponding rotation of the end caps 888 and 890. Rotation of the end caps 888 and 890 causes corresponding rotation of the shaft 800. The shaft 800 will rotate relative to the shaft covers 822 and 824, which do not rotate relative to the housing 702. The inward force of the shaft caps 822 and 824 on the shaft 800 due to the action of the biasing mechanism 836 on the shaft caps 822 and 824 causes a frictional force between the shaft 800 and the shaft caps 822 and 824 that resists rotation of the shaft 800. Tension is induced in the film 884 pulled from the supply roll 882 against rotation of the shaft 800 relative to the shaft covers 822 and 824. In embodiments where the inward force of the shaft caps 822 and 824 on the shaft 800 is substantially constant (e.g., when the biasing mechanism 836 is a constant force spring), the tension induced in the deployed membrane 884 is substantially constant.

The shaft assembly 820 and supply roll 882 can be used with a plurality of film supply rolls, including supply rolls having different sizes. For example, the shaft assembly 820 may be removed from the position in the housing 702 shown in fig. 20C by lifting the shaft assembly 820 such that the keyed end 830 of the shaft cover 830 slides up and out of the slots 740 and 742. End caps 888 and 890 may then be slid off shaft 800 and removed from supply roll 882. End caps 888 and 890 may then be placed on another supply roll, such as supply roll 892 of film 894. The supply roll 882 includes a core 886 around which the film 894 has been wound. The end caps 888 and 890 may be inserted into both ends of the hollow bore of the core 896.

After end covers 888 and 890 are placed on supply roll 892, supply roll 892 and end covers 888 and 890 may be slid onto shaft 800. In the illustrated embodiment, the end cap 888 can be slid onto the right end of the shaft 800 (as viewed in fig. 20D), the end cap 888 can be slid to the left until the end cap 890 is also slid onto the right end of the shaft 800, and then the end caps 888 and 890 can be slid further to the left until the end cap 888 contacts the clip 825 and the supply roll 892 and the end caps 888 and 890 are in the position shown in fig. 20D.

With supply roll 892 and end caps 888 and 890 loaded onto shaft assembly 820, shaft assembly 820 may be placed into housing 702 of membrane inflation system 700. In some embodiments, the shaft assembly 820 is placed into the housing 702 of the membrane inflation system 700 by: the keyed ends 830 of the shaft covers 822 and 824 are slid through the slots 740 and 742, respectively, until the shaft assembly 820 is in the position depicted in fig. 20D. In the illustrated position, the bonding end 830 and the slots 740 and 742 are shaped to prevent rotation of the shaft covers 822 and 824 relative to the housing 702.

With the shaft assembly 820 placed into the housing 702 of the film inflation system 700, the film 894 can be withdrawn from the supply roll 892 to supply the film 894 to the film inflation assembly. For example, film 894 may be fed from supply roll 892 to roller assembly 712, and roller assembly 712 may feed film 894. When film 894 is retrieved from supply roll 892, the retrieval of film 894 will cause supply roll 892 to rotate relative to housing 702. Rotation of supply roll 892 causes corresponding rotation of end caps 888 and 890. Rotation of the end caps 888 and 890 causes corresponding rotation of the shaft 800. The shaft 800 will rotate relative to the shaft covers 822 and 824, which do not rotate relative to the housing 702. The inward force of the shaft caps 822 and 824 on the shaft 800 due to the action of the biasing mechanism 836 on the shaft caps 822 and 824 causes a frictional force between the shaft 800 and the shaft caps 822 and 824 that resists rotation of the shaft 800. Tension is induced in the film 894 pulled from the supply roll 892 against rotation of the shaft 800 relative to the shaft covers 822 and 824. In embodiments where the inward force of the shaft caps 822 and 824 on the shaft 800 is substantially constant (e.g., when the biasing mechanism 836 is a constant force spring), the tension induced in the deployed membrane 894 is substantially constant.

One difference between supply roll 882 and supply roll 892 depicted in fig. 20C and 20D is their width difference. More specifically, supply roll 882 has a width W₁And supply roll 892 has a width W₂. In the illustrated embodiment, the width W₁Is greater than width W₂. As is apparent when viewing fig. 20C and 20D, the same tension inducing axle assembly 820 can be used with films of different widths and induce tension in the film being withdrawn from the supply roll regardless of the width of the supply roll placed on the axle assembly 820.

For purposes of this disclosure, terms (e.g., "upper," "lower," "vertical," "horizontal," "inward," "outward," "inner," "outer," "front," "rear," etc.) should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms "connected," "coupled," and "mounted," and variations thereof herein, are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless otherwise specified, the terms "substantially", "about", and the like are used to mean within 5% of the target value.

The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, the aspects of the present disclosure that are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be considered as illustrative and not restrictive. It will be understood that modifications and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the claimed disclosure.