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 novel dunnage-creating machine and methodology characterized by various features including, inter alia, a modular construction, easier access to interior components, and a low cost cutting assembly. The machine comprises front and rear units having separate housings. The housing of the rear unit includes an outer shell having a converging chute surrounding a shaping member over which sheet-like stock material is drawn to form the stock material into a three-dimensional shape. The front unit includes in the housing thereof a feed mechanism for drawing the stock material over the shaping member and stitching the shaped material to form a strip of dunnage product. The front unit also includes a manual cutting mechanism for cutting the strip to form cut pieces, which manual cutting mechanism includes a readily replaceable blade assembly.

Abstract: A cushioning conversion machine (20) for converting sheet-like stock material (22) into a three-dimensional cushioning product (P) including a device (400; 400′; 500; 600; 600′; 700) which controls the width of the strip and which may be selectively adjusted to change the width of the strip. By selectively setting the device (400, 400′, 500; 600; 600′; 700), a cushioning product of a desired width may be produced. For more sophisticated packaging needs, the stock material may be converted into a first portion of a certain width, the device adjusted, and then the stock material may be converted into a second portion of a different width whereby the cushioning product will have continuous portions of different widths.

Abstract: A monitoring system for monitoring one or more packaging material conversion machines includes one or more sensors for monitoring one or more operating characteristics of the one or more conversion machines. The system also includes a controller in communication with the one or more sensors. The controller evaluates the one or more operating characteristics of the one or more conversion machines to thereby provide diagnostic, inventory and machine usage information. In addition, a method of monitoring one or more packaging material conversion machines includes sensing an operating characteristic of the one or more conversion machines and evaluating the operating characteristic of the one or more conversion machines. The sensed operating characteristics may be evaluated either local to the conversion machines or at a remote site, thereby providing a substantial amount of flexibility.

Abstract: A cushioning conversion system includes a cushioning conversion machine which converts stock paper into a plurality of cut pads, and a conveyor system positioned to receive pads produced by the cushioning conversion machine and including a conveyor which conveys the pads away from the machine and at least one moveable gate having an open position allowing a pad to pass, therethrough and a closed position for stopping progress of a pad along the conveyor when there is insufficient space on the conveyor downstream of the gate to permit a pad to progress substantially through the gate.

Abstract: A cushioning conversion machine for converting sheet-like stock material into a relatively low density cushioning dunnage product. The machine has at least one conversion assembly for forming the stock material into a three-dimensional shape. The machine includes a feed mechanism for drawing the stock material over a shaping member in the conversion assembly. Any one of a plurality of manually operated severing mechanisms can be mounted in the second unit for cutting the cushioning dunnage product into cut sections. One severing unit has a circular cutting disc which is driven by a rack and pinion faster than rolling contact along a reaction member. Another severing mechanism has a fixed blade with an inclined cutting edge that moves across the path of the converted material. A third mechanism has straight edged blade that moves on vertical tracks downward through the path of the emerging converted material to sever the material against a fixed reaction member.

Abstract: A cushioning conversion machine includes a plurality of laterally spaced apart upstream assemblies which advance the sheet stock material with a transversely reciprocating twisting motion and at least one downstream assembly that retards the advance of the stock material. Additionally, the upstream assemblies feed the sheet stock material at a feed rate greater than the feed rate at which the downstream assembly passes the sheet stock material. The downstream assembly thereby cooperates with the upstream assemblies to crumple the stock material and impart loft thereto, and as a further result, the crumpled stock material includes a regular arrangement of folds preferably forming a herringbone pattern.

Abstract: A pad production (supply) and packaging system, and method, for automatically producing dunnage pads and inserting one or more of the produced dunnage pads into a container for packaging of an article in the container. The invention is characterized by a pad discharge assembly and/or pad insertion assembly to provide an automatic pad production and packaging system, and method, that afford advantages over existing pad production and packaging arrangements. The discharge assembly, which provides for controlled discharge of dunnage pads produced by a pad producing machine, includes a gating device for effecting passage of the pad out of the holding zone in a direction transverse to the pad length. A controller causes the discharge assembly to release a pad held in the holding zone for passage onto a working surface and preferably a conveyor in synchronous relation to movement of the conveyor for controlled deposition of pads onto the conveyor.

Abstract: A safety output chute for a cushioning conversion machine includes a chute having an input end and an output end, the input end including an opening for receiving a flexible cushioning product from an outlet of the cushioning conversion machine; and a plurality of rollers situated inside the chute, the rollers being oriented such that the flexible cushioning product must follow a non-linear path from the input end of the chute to the output end of the chute. Other embodiments of a safety output chute are also disclosed.

Abstract: A cushioning conversion system including a cushioning conversion machine having conversion assemblies for converting a sheet stock material into a relatively lower density cushioning dunnage product, a stand for supporting the cushioning conversion machine at a convenient height and/or angular orientation, and a stock supply cart including a dancer roller for helping to maintain a greater uniformity of tension on the sheet material being fed through the conversion assemblies from changes in loads acting on the sheet material upstream of the dancer roller regardless of the angular orientation of the cushioning conversion machine.

Abstract: Cushioning conversion stitching/coining members each include a plurality of radially outwardly extending projections that meshingly engage during rotation. One stitching member includes a recess and the other stitching member includes cutting edges received in the recess to cut a row of slits in the overlapped portions of the stock material to form at least one row of tabs for interlocking the overlapped portions of the stock material. The cutting edges are radially positioned between adjacent projections of the second stitching member and circumferentially spans less than the circumferential space between adjacent projections. Additionally or alternatively, the projections are shaped so that there is exaggerated backlash between meshing projections.

Abstract: A cushioning conversion machine for converting sheet-like stock material into cut sections of a pad-like cushioning dunnage product is provided. The machine includes a frame, conversion assemblies which convert the sheet-like stock material into the cushioning dunnage product, and a cutting assembly (56) which cuts the cushioning dunnage product into cut sections. The frame (46) includes an outlet opening (48) through which the cushioning dunnage product emerges. The cutting assembly (56), which is mounted downstream of the outlet opening (48), comprises a first blade (160) and a second blade (162). The second blade (162) is mounted on the frame (46) in such a manner that it travels between a rest position whereat it is removed from the first blade (160) to a cutting position whereat it coacts with the first blade (160) to cut the cushioning dunnage product into a cut section.

Abstract: A novel cushioning conversion machine and method for converting sheet stock material into a novel cushioning product and for producing discrete sections or pads of desired length, without the need for a cutting assembly, thereby enabling the construction of a less expensive, smaller and less complex machine. The machine and method are characterized by a weakening device for perforating a sheet stock material of one or more plies along tear lines so that as a strip of cushioning is formed from the stock material, discrete sections or pads of desired length may be detachable along the tear lines. The stock material includes material which is biodegradable, recyclable and composed of a renewable resource, such as Kraft paper.

Abstract: A cushioning product including a pillow-like portion made from multiple plies of a sheet-like stock material. The cushioning product is characterized by the pillow-like portion including an inner stuffing and a shell which surrounds the inner stuffing. The multiple plies of the sheet-like stock material include at least one ply shaped to form the shell of the pillow-like portion and remaining plies crumpled to form the inner stuffing. The inner stuffing is formed only from the remaining plies of the sheet-like stock material.

Abstract: A cushioning conversion system comprising a cushioning conversion machine, a packaging surface, and a dispenser. The cushioning conversion machine includes a conversion assembly which converts a sheet-like stock material into cushioning pads. The dispenser includes a receptacle in which the pads are placed in a vertical stack as they are produced by the cushioning conversion machine. The receptacle is positioned above the packaging surface when the pads are selectively withdrawn therefrom to package items on the packaging surface. The cushioning conversion system allows the accumulation of a plurality of cushioning pads for selective withdrawal without the packaging person having to bend over, without sacrificing valuable packaging surface space, and/or without substantially increasing the system's footprint.

Abstract: A cushioning conversion machine located below a work table includes a stock supply assembly, a conversion assembly for converting the stock material into a cushioning product and providing it through a machine exit, and a pad transferring system including an upper series of rollers arranged in a path, a lower series of rollers arranged in a path and a motor for powering the rotation of the drive elements, the upper and the lower series of rollers defining a path therebetween leading from the machine exit to a passage in the work table.

Abstract: A packaging system and method according to the invention are generally characterized by a cushioning conversion machine for forming and dispensing cut sections of a cushioning product through a discharge outlet, an inclined dispensing chute for sequentially receiving the cut sections of the cushioning product, a cut section presence detector for detecting the presence of a cut section on the inclined chute at a pick-up location remote from the discharge outlet of the conversion machine, and a controller which initiates dispensing of a cut section of cushioning product in response to a detected absence of a cut section by the cut section presence detector.