Abstract: A self-leveling bin assembly includes a docking station, a bin received in or on the docking station, a bottom member or parts tray movably received in the bin, and a lifting mechanism provided as part of the docking station. The lifting mechanism is configured to lift or raise the parts tray within the bin as associated material located on the parts tray is selectively removed.

Abstract: A self-leveling bin assembly includes a docking station, a bin received in or on the docking station, a bottom member or parts tray movably received in the bin, and a lifting mechanism provided as part of the docking station. The lifting mechanism is configured to lift or raise the parts tray within the bin as associated material located on the parts tray is selectively removed.

Abstract: A system, and associated components and methodology, having a dunnage supply with an outlet through which one or more crumpled strips are supplied, a positioning device that positions in juxtaposition portions of the one or more strips of dunnage, and a stapler for connecting the juxtaposed portions to hold them together. In a particular system, the system includes a converter that has a conversion assembly that converts a sheet stock material into a crumpled strip of dunnage and has an outlet through which the strip of dunnage is emitted. The system also includes a coiler that rolls the strip of dunnage into a coil, and a stapler that secures the trailing end portion of the strip of dunnage to at least the next-innermost portion of the strip in the coil by inserting a staple through the trailing end portion and the juxtaposed portion of the coiled strip.

Abstract: A dunnage conversion machine (115), wherein sheet stock material is crumpled to form a crumpled strip, includes a feeding assembly (132). The feeding assembly (132) includes opposed feeding members that engage and advance the crumpled strip therebetween. One of the feeding members (141) includes a rotating member (141) supported on a shaft (144) for rotation about the axis of the shaft, the shaft being mounted for transverse movement toward and away from the other feeding member (140) to accommodate variations of the thickness of the crumpled strip as it is advanced between the opposed feeding members (140 and 141). The conversion machine (115) also includes a guide member (200) positioned laterally adjacent to the rotating member (141) progressively to guide a portion of the crumpled strip underneath the shaft (144). The guide member (200) has at least a portion adjacent the shaft (144) that is transversely movable.

Abstract: A system, and associated components and methodology, having a dunnage supply with an outlet through which one or more crumpled strips are supplied, a positioning device that positions in juxtaposition portions of the one or more strips of dunnage, and a stapler for connecting the juxtaposed portions to hold them together. In a particular system, the system includes a converter that has a conversion assembly that converts a sheet stock material into a crumpled strip of dunnage and has an outlet through which the strip of dunnage is emitted. The system also includes a coiler that rolls the strip of dunnage into a coil, and a stapler that secures the trailing end portion of the strip of dunnage to at least the next-innermost portion of the strip in the coil by inserting a staple through the trailing end portion and the juxtaposed portion of the coiled strip.

Abstract: A dunnage conversion machine (115), wherein sheet stock material is crumpled to form a crumpled strip, includes a feeding assembly (132). The feeding assembly (132) includes opposed feeding members that engage and advance the crumpled strip therebetween. One of the feeding members (141) includes a rotating member (141) supported on a shaft (144) for rotation about the axis of the shaft, the shaft being mounted for transverse movement toward and away from the other feeding member (140) to accommodate variations of the thickness of the crumpled strip as it is advanced between the opposed feeding members (140 and 141). The conversion machine (115) also includes a guide member (200) positioned laterally adjacent to the rotating member (141) progressively to guide a portion of the crumpled strip underneath the shaft (144). The guide member (200) has at least a portion adjacent the shaft (144) that is transversely movable.

Abstract: A dunnage converter system (10), components and method are disclosed. A support device (14) supporting one or more stacks (61-65) of fan-folded sheet stock material is provided. Stock material is supplied from the support device (14) to a dunnage converter (12) when the support device (14) is positioned in proximity thereto. A supply of sheet stock material (18) for use with a dunnage converter includes at least one continuous ply of sheet stock material that is fan-folded, and includes a series of folds that together form a sequence of rectangular pages, the pages being piled accordion style one on top of the other to form the stack(s) (61-65) of sheet stock material.

Abstract: A cushioning conversion machine (20) including a conversion assembly (30) which converts a continuous sheet of multi-ply stock material (22) into a three dimensional cushioning product (32) and a stock supply assembly (550) which supplies the multi-ply stock material (22) to the conversion assembly (30). The conversion assembly (30) includes a forming assembly (52) which inwardly turns lateral portions of the stock material (22) as the stock material (22) travels therethrough in a downstream direction. The stock supply assembly (550) includes a separating device (574) and/or constant-entry device (580) designed to minimize tearing due to excessive tension in the lateral regions of the stock material (22). Additionally or alternatively, the forming assembly (52) includes a shaping member (590) having protrusions in its turning perimeter and/or holding surface to modify the shape of the cushioning product.

Abstract: A cushioning conversion system and method for transferring a dunnage pad are disclosed. The conversion system includes a cushioning conversion machine and a pad support. The conversion machine produces cushioning dunnage pads and discharges the pads in a predetermined discharge direction. A pad support is movable between a pad receiving position and a pad discharge position. In the pad receiving position, the pad support is oriented relative to the conversion machine to receive thereon dunnage pads discharged from the conversion machine in the discharge direction. In the pad discharge position, the pad support is tilted relative to horizontal for discharge of the dunnage pad from the pad support.

Abstract: A cushioning conversion machine having a novel former around which a sheet material is folded to form an improved cushioning product. The former has longitudinally spaced side surfaces inclined from bottom to top toward a downstream end of the machine. The side surfaces cause the obstruction of the sheet stock material upstream of the side surfaces so that the sheet material crumples in the spaces upstream of the side surfaces, thereby increasing the cushioning properties of pillow portions of the cushioning product. The former also has a centrally located base plate which minimizes crumpling in a central portion of the sheet material so that the folded over portions and the central portion can be connected to maintain more effectively the shape of the pillow portions in the resulting cushioning product. In addition, the former has a guard plate mounted above longitudinally spaced bottom edges extending laterally outwardly from the base plate and upstream from a vertical central plane.

Abstract: A cushioning conversion machine (20) including a conversion assembly (30) which converts a continuous sheet of multi-ply stock material (22) into a three dimensional cushioning product (32) and a stock supply assembly (550) which supplies the multi-ply stock material (22) to the conversion assembly (30). The conversion assembly (30) includes a forming assembly (52) which inwardly turns lateral portions of the stock material (22) as the stock material (22) travels therethrough in a downstream direction. The stock supply assembly (550) includes a separating device (574) and/or constant-entry device (580) designed to minimize tearing due to excessive tension in the lateral regions of the stock material (22). Additionally or alternatively, the forming assembly (52) includes a shaping member (590) having protrusions in its turning perimeter and/or holding surface to modify the shape of the cushioning product.

Abstract: A cushioning conversion system (20; 120; 320) and method for making a coil of cushioning product, including a cushioning conversion machine (22; 122; 322) and a coiler (24; 124; 224; 324). As a strip of cushioning product (S) is emitted from the cushioning conversion machine (22; 122; 322), the coiler (24; 124; 224; 324) rolls the strip of cushioning product (S) into a coiled configuration to form a coil of cushioning product (C). The coiler (24; 124; 224; 324) is adapted to allow the coil of cushioning product (C) to be removed in its coiled configuration. The cushioning conversion system may also include a guide device (26; 326), which guides the strip of cushioning product from the cushioning conversion machine's outlet (34) to the coiler (24; 124; 324), and/or a controller (28; 328), which controls the coiler (24; 124; 224; 324) based on the production of the cushioning conversion machine (22; 122; 322).

Abstract: A cushioning conversion machine (100, 200, 300, 400, 500, 600, 700, 800, 900) comprising a conversion assembly (101, 201, 301, 401, 501, 601, 701, 801, 901) which converts a sheet stock material into a three-dimensional strip of cushioning. The conversion assembly (101, 201, 301, 401, 501, 601, 701, 801, 901) includes a forming assembly (120, 220, 320, 420, 520, 620, 720, 820, 920) that forms the stock material into a strip of stock material. The forming assembly (120, 220, 320, 420, 520, 620, 720, 820, 920) comprises an external forming device (122, 222, 322, 422, 522, 622, 722, 822, 922) and an internal forming device (124, 224, 324, 424, 524, 624, 724, 824, 924). The internal forming device (124, 224, 324, 424, 525, 624, 724, 824, 924) includes interacting and/or mandrel portions (164, 264, 364, 464, 564, 664, 764, 864, 964) which internally interact with lateral portions of the strip of stock material to internally reshape the cross-sectional geometry of the strip.

Abstract: A cushioning conversion machine (20) including a conversion assembly (30) which converts a continuous sheet of multi-ply stock material (22) into a three dimensional cushioning product (32) and a stock supply assembly (550) which supplies the multi-ply stock material (22) to the conversion assembly (30). The conversion assembly (30) includes a forming assembly (52) which inwardly turns lateral portions of the stock material (22) as the stock material (22) travels therethrough in a downstream direction. The stock supply assembly (550) includes a separating device (574) and/or constant-entry device (580) designed to minimize tearing due to excessive tension in the lateral regions of the stock material (22). Additionally or alternatively, the forming assembly (52) includes a shaping member (590) having protrusions in its turning perimeter and/or holding surface to modify the shape of the cushioning product.

Abstract: A system that converts the stock material into a cushioning product has associated therewith a conversion assembly which converts the stock material into the cushioning product and a stock roll loading assembly. The stock roll loading assembly includes a frame, a stock roll transfer member, and a ramp. The stock roll transfer member is mounted to the frame for movement between a load position whereat a stock roll may be loaded thereon and a release position whereat the stock roll is released from the transfer member. The ramp receives the stock roll from the transfer member and conveys the stock roll to a position remote from the release position. In an embodiment, the stock roll transfer member is loaded from an end thereof. In another embodiment, the stock roll transfer member is loaded from the side thereof. A stock roll storage assembly stores one or more stock rolls and enables the stock rolls to be sequentially released from the ramp.

Abstract: A cushioning conversion system and method for transferring a dunnage pad are disclosed. The conversion system includes a cushioning conversion machine and a pad support. The conversion machine produces cushioning dunnage pads and discharges the pads in a predetermined discharge direction. A pad support is movable between a pad receiving position and a pad discharge position. In the pad receiving position, the pad support is oriented relative to the conversion machine to receive thereon dunnage pads discharged from the conversion machine in the discharge direction. In the pad discharge position, the pad support is tilted relative to horizontal for discharge of the dunnage pad from the pad support.

Abstract: A cushioning conversion machine having a novel former around which a sheet material is folded to form an improved cushioning product. The former has longitudinally spaced side surfaces inclined from bottom to top toward a downstream end of the machine. The side surfaces cause the obstruction of the sheet stock material upstream of the side surfaces so that the sheet material crumples in the spaces upstream of the side surfaces, thereby increasing the cushioning properties of pillow portions of the cushioning product. The former also has a centrally located base plate which minimizes crumpling in a central portion of the sheet material so that the folded over portions and the central portion can be connected to maintain more effectively the shape of the pillow portions in the resulting cushioning product. In addition, the former has a guard plate mounted above longitudinally spaced bottom edges extending laterally outwardly from the base plate and upstream from a vertical central plane.

Abstract: A cushioning conversion machine including a conversion assembly which converts a sheet stock material into a relatively less dense cushioning product. The conversion assembly includes a forming assembly, having an external forming device and an internal forming device positioned at least partially within the external forming device, the forming assembly inwardly turning lateral regions of the sheet stock material as the sheet stock material travels through the forming assembly in an upstream to downstream direction. The sheet stock material passes between the external forming device and the internal forming device as it travels through the forming assembly. The internal forming device has a central guide portion with a bottom guide surface which guides a central region of the sheet stock material as its lateral regions are inwardly turned, and a cascade portion having stages disposed above the bottom guide surface of the central guide portion.

Abstract: A cushioning conversion machine (20) including a conversion assembly (30) which converts a continuous sheet of multi-ply stock material (22) into a three dimensional cushioning product (32) and a stock supply assembly (550) which supplies the multi-ply stock material (22) to the conversion assembly (30). The conversion assembly (30) includes a forming assembly (52) which inwardly turns lateral portions of the stock material (22) as the stock material (22) travels therethrough in a downstream direction. The stock supply assembly (550) includes a separating device (574) and/or constant-entry device (580) designed to minimize tearing due to excessive tension in the lateral regions of the stock material (22). Additionally or alternatively, the forming assembly (52) includes a shaping member (590) having protrusions in its turning perimeter and/or holding surface to modify the shape of the cushioning product.

Abstract: A cushioning conversion system (10) and method wherein a stock roll storage rack (14) is used to support at least one and preferably a plurality of stock rolls (21) at the same level as the stock roll holder (19) of a cushioning conversion machine (12). The stock roll storage rack (14), which stores the stock rolls (21) in a substantially horizontal array, enables an operator to easily load the machine (12) without having to lift a stock roll (21) to the height of the stock roll holder (19). Also, plural stock roll storage racks (14) can be used interchangeably, whereby one can be loaded with stock rolls (21) by an attendant while the other is used to load stock rolls (21) onto the cushioning conversion machine (12). The stock roll storage rack (14) includes a stand (70) and a stock roll storage shelf (72) vertically adjustable on the stand (70) to match the height of the storage shelf (72) to the height of a stock roll holder (19) on the conversion machine (12).