Abstract: A dunnage system may include a converting station including a converter configured for pulling in a stream of sheet material and converting the material into dunnage, and an inlet guide having an inlet surface that is coiled such that first and second ends of the inlet surface are discontinuous with each other to define a gap therebetween, the inlet surface configured to channel the sheet material into the converter. A cutter for a dunnage system may include a blade with first and second phases of serrations that are coextensive over at least a portion of the blade, the first phase providing cutting serrations for cutting the dunnage, and the second phase comprising ledges for focusing the cutting and preventing or reducing bunching of the dunnage towards a side of the blade. A method of converting dunnage may also be provided.

Abstract: A method for making an expansion wall is provided. The method can include applying a matrix to a first ply and applying an expansion element to the surface of the matrix. A second ply is applied over the first ply to trap the matrix and expansion element therebetween. The applied expansion element is entrained into the applied matrix to provide an expansion material that is configured to expand to, and solidify in, an expanded condition upon activation.

Abstract: Envelopes for holding one or more items include a first and a second flexible wall. The second wall overlies, and is affixed to the first flexible wall. The second flexible wall can include a plurality of overlying layers of paper affixed to each other so as to define an interlayer region within which at least two of the plurality of overlying layers of paper are not adhered to each other.

Abstract: Disclosed is a dunnage apparatus, including a converting station and a deflector. The converting station converts a line of high-density supply material into low-density dunnage and ejects the dunnage at an exit in an exit trajectory along a path. The deflector is repositionable with respect to the exit between a first position, in which the deflector is interposed in the path to deflect the path of the dunnage from the exit trajectory to a first deflected trajectory, and a second position. The deflector is retained in each position during the ejection of the dunnage.

Abstract: A protective packaging web is disclosed. The web includes a first film web having a plurality of extended portions including a base perimeter enclosing an open base region and an extended surface protruding in one direction from a plane defined by the first film web. The extended surface has a larger surface area than the open base region. The web also includes a second film web sealed to the first film web around a portion of the open base region to form sub-chambers on a side of the first film web opposite the protruding direction. The first film web and the second film web remain unsealed across the open base region defining regions within the sub-chambers suitable to contain a fluid volume. The plurality of sub-chambers are interconnected via one or more intra-chamber channels, allowing each of the sub-chambers to receive and release fluid in response to external pressures.

Abstract: Disclosed herein are protective packaging stock material units that are used in a dunnage system. A dunnage system includes a dunnage conversion machine and a supply station. The supply station is configured to receive fanfold stock material and manipulate the fanfold stock material into being withdrawn from the supply station in a non-planar configuration. The supply station is associated with the dunnage conversion machine such that the dunnage conversion machine operably draws fanfold stock material from the top of a stack of fanfold stock material.

Abstract: A roll dispenser is arranged to support a roll of packaging material, and includes a chuck assembly with a first chuck unit that includes a first plug received in a first axial end of a core of the roll, a first shaft fixed to the first plug, a first mount brought into engagement with the first shaft, and a first brake connected to the first plug and the first mount to establish friction between the first plug and the first mount. A first handle assembly may adjust a first compressive force applied axially between the first mount and the first shaft to regulate the friction between the first plug and the first mount. The chuck assembly also may include a second chuck unit received in a second axial end of the core for additionally supporting the roll of packaging material.

Abstract: Packaging material is provided. The packaging material can include at least one web layer having a surface that includes first and second regions. When corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions can cooperatively surround a cavity. The packaging material further can include a first sealing material disposed in the first region and configured to seal together the corresponding first regions upon application of first conditions to the first sealing material, and a second sealing material disposed in the second region and configured to seal together the corresponding second regions upon application of second conditions to the second sealing material. The second sealing material can be configured such that the first conditions applied to the second sealing material are insufficient to cause the second sealing material to seal.

Abstract: A conversion apparatus is provided herein. The conversion apparatus includes a cutting member having an edge configured for cutting the dunnage material. The conversion apparatus also includes a biasing member that is located adjacent to the cutting member such that the dunnage material passes between the biasing member and the cutting member. The biasing member operably contacts the dunnage material thereby biasing the dunnage material against the cutting member. The position of the biasing member relative to the cutting member is such that in response to the dunnage material being retracted back into the conversion apparatus the cutting member begins to sever the dunnage material, but in response to the dunnage material traveling in the dispensing direction the cutting member does not begin to sever the dunnage material due to the relative position.

Abstract: Stock material units that may be used in a dunnage conversion machine. For example, stock material units include sheet material that may be fed into the dunnage conversion machine and may be converted thereby into dunnage.

Abstract: A dunnage conversion machine includes a drive mechanism configured to deform a stock material into a continuous length of dunnage. The machine also includes a cutting device configured to sever a piece of the dunnage from the continuous length of dunnage. The cutting device includes a grip configured to move to a closed position at which the grip exerts a force on the piece of dunnage to retain the piece on the machine until the piece is pulled away from the machine, at which point the grip moves to an open position and the machine advances the continuous length of dunnage to commence another cutting cycle.

Abstract: A dunnage system may include a converting station including a converter configured for pulling in a stream of sheet material and converting the material into dunnage, and an inlet guide having an inlet surface that is coiled such that first and second ends of the inlet surface are discontinuous with each other to define a gap therebetween, the inlet surface configured to channel the sheet material into the converter. A cutter for a dunnage system may include a blade with first and second phases of serrations that are coextensive over at least a portion of the blade, the first phase providing cutting serrations for cutting the dunnage, and the second phase comprising ledges for focusing the cutting and preventing or reducing bunching of the dunnage towards a side of the blade. A method of converting dunnage may also be provided.

Abstract: The present disclosure relates to inflatable flexible structures. An inflation region may run longitudinally through the inflatable flexible structure allowing the inflation of chambers. The inflatable chambers may be separable at transverse lines of weakness formed by perforations. The inflation conduit may be free of the perforation. Additionally or alternatively, the perforations may be chevron shaped.

Abstract: A dunnage conversion machine includes a drive mechanism configured to deform a stock material into dunnage. The drive mechanism may include a roller with an outer surface having a first shape, and another roller having an outer surface with a second shape different than the first shape. The dunnage conversion machine also may include a cutting mechanism that includes an anvil having a curvilinear surface, and a cutting portion, with the anvil and the cutting portion being configured to cut the dunnage. The dunnage conversion machine also may include an inlet chute configured to feed the stock material to the dunnage conversion machine. The inlet chute may include a protrusion located within an interior channel of the inlet chute and configured to restrict larger objects, such as the fingers and hands of an operator, from moving down the interior channel.

Abstract: An inflatable protective packaging unit and associated inflation systems are disclosed. The unit can include an inflatable component that includes overlaid flexible plies connected to each other to define a fluid chamber therebetween. The inflatable component can define an inflation region in fluid communication with the fluid chamber to allow fluid from the inflation region into the fluid chamber. The unit can further include a receiver separably attached to the inflatable component at the inflation region and configured to direct fluid into the inflation region. The inflation system can be configured to discretely engage the inflatable protective packaging unit and provide fluid for inflation. Once inflated, the system may eject the unit, and cause the inflatable component to separate from the receiver.

Abstract: A stock material unit for a dunnage conversion machine is provided herein. The stock material includes a first strip of sheet material at least partially defining a three-dimensional configuration. The strip of sheet material includes a first end and a second end opposite the first end. The stock material includes a splice member mounted with respect to the sheet material in a first position. The splice member includes a connector that has a bonding member configured to stick to the first end. The connector is releasable from the first position and repositionable to a second position in which it is affixed to the first end by a connecting portion. In the second position, the connecting portion has an exposed area for affixing to a second end of a second continuous sheet of the material to daisy chain the first and second strips of sheet material.

Abstract: Packaging material is provided. The packaging material can include at least one web layer having a surface that includes first and second regions. When corresponding first regions are overlaid with each other and corresponding second regions are overlaid with each other, the overlaid first and second regions can cooperatively surround a cavity. The packaging material further can include a first sealing material disposed in the first region and configured to seal together the corresponding first regions upon application of first conditions to the first sealing material, and a second sealing material disposed in the second region and configured to seal together the corresponding second regions upon application of second conditions to the second sealing material. The second sealing material can be configured such that the first conditions applied to the second sealing material are insufficient to cause the second sealing material to seal.

Abstract: An inflatable web is disclosed. The web includes first and second film plies sealed together via a plurality of generally transverse seals to define a first and second inflatable chambers and an inflation region. The chambers are inflatable with a fluid and operable to contain the fluid. The sealed plies have a first longitudinal edge and a second longitudinal edge. The web defines a separation region extending at least partially transversely across the web between the first and second inflatable chambers and is configured to facilitate separation thereof. The separation region includes a tear propagation line extending transversely across at least a portion of the web with an end of the tear propagation line terminating proximal to the first longitudinal edge of the web. The separation region includes a tear initiation feature including edges spaced apart from one another longitudinally to form a permanent opening in the web.

Abstract: A transfer and dispensing apparatus is disclosed for the conveying and separation of packaging material, cushions or pillows when needed by the operator. When a packer working over a conveyor receives a box that requires void fill, an operating switch such as a foot pedal is depressed to dispense pillows from the apparatus and into the box in a connected strip. When the operating switch is released, the apparatus stops dispensing pillows, separates the continuous strip of pillows along a transverse perforation in the strip, and ejects the end of the separated segment. The packer can then complete packing the box by placing the severed end of the pillows into the box, advance to the next box, and repeat the process. The transfer and dispensing apparatus may be positioned in any convenient location including adjacent to, above or attached to the inflation device.

Abstract: The present disclosure relates generally to an inflation and sealing machine and in particular to a method for modifying one or more parameters of the machine. The method includes identifying a configuration of a supply material to be used with the inflation and sealing machine, such as by receiving a user input, automatically detecting characteristics of the material, and/or receiving data such as from a sensor regarding the characteristics of the material. Once the configuration of the supply material is identified, the method includes receiving a selection of a prestored recipe according to a configuration of the supply material, where the recipe determines or sets the value for one or more operating parameters of the machine.