Abstract: A supply of single-ply, fan-folded sheet stock material (100) includes a holder that has inclined support surfaces (114, 116, 120, 122) and intersecting support walls (124, 126) that support the support surfaces in their inclined orientations. The holder has a W-shape cross-section, with inclined outer support surfaces (114, 116) and inclined inner support surfaces (120, 122) that may meet in the middle. The inner support surfaces generally are perpendicular to adjacent outer support surfaces to support a generally rectangular stack (102) and sub-stacks (110, 112) of single-ply, fan-folded sheet stock material. A method includes laying open a stack of single-ply fan-folded sheet stock material to form two sub-stacks of sheet stock material and operating a dunnage conversion machine to simultaneously draw sheet stock material from both sub-stacks of sheet stock material, thereby providing a two-ply sheet stock material for conversion into a dunnage product.

Abstract: A dunnage conversion machine converts a sheet stock material into a dunnage product that is relatively thicker and less dense than the stock material. The conversion machine includes a conversion assembly that draws the sheet stock material therethrough and randomly crumples at least a portion of the sheet stock material. Before severing a discrete dunnage product of a desired length from the substantially continuous length of sheet stock material, the conversion assembly temporarily advances the sheet stock material therethrough while minimizing or eliminating the random crumpling of the sheet stock material in a reduced-crumpling zone, and then cuts the sheet stock material in the reduced-cutting zone to reduce or eliminate the production of scrap shards of sheet stock material.

Abstract: A machine for converting a sheet stock material into a relatively less dense dunnage product includes both (a) a helical pre-form assembly having a cylindrical mandrel with a longitudinal axis and a guide member for guiding the sheet stock material from a supply thereof into a helical path along and around the mandrel so as to form a helical pre-form that rotates around the longitudinal axis and advances parallel to the longitudinal axis; and (b) a restriction in the path of the pre-form that slows the advance and rotation of the pre-form past the restriction, the restriction causing the pre-form to retard longitudinal advancement, to twist upon itself, and to permanently deform as it moves past the restriction, thereby longitudinally and helically crumpling the pre-form.

Abstract: An improved expandable slit-sheet stock material is configured to aid in temporarily restricting opening of a plurality of slits of the slit-sheet stock material, such as during winding of the unexpanded stock material or during expansion of the stock material. Each slit of the plurality of slits includes one or more un-slit reinforcement portions, such as reinforcement ties, extending fully between opposite longitudinal sides of the slit, and disposed between opposed transverse endpoints of the slit. The reinforcement ties minimize or prevent tearing of the stock material during the winding or expansion. A dunnage conversion system for expanding the slit-sheet stock material includes an expander having a pair of opposed rollers. The rollers engage the stock material to effect breaking of the un-slit reinforcement portions and expansion of the slit-sheet stock material.

Abstract: A dunnage conversion machine (36) converts a sheet stock material into a dunnage product that is relatively thicker and less dense than the stock material, but is relatively thin and sufficiently flexible to function as a protective wrap. The conversion machine includes a feed mechanism (40) that advances a sheet stock material therethrough and a connecting mechanism (42) downstream of the feed mechanism. The connecting mechanism retards the passage of the sheet stock material therethrough by feeding the stock material therethrough at a slower rate than the feed mechanism feeds the stock material to the connecting mechanism. This causes the stock material to randomly crumple in a longitudinal space between the feed mechanism and the connecting mechanism. The connecting mechanism connects multiple overlapping layers of sheet stock material together as they pass therethrough, including connecting at least one crumpled sheet to one side of one other sheet.

Abstract: A dunnage conversion machine converts a sheet stock material into a dunnage product that is relatively thicker and less dense than the stock material. The conversion machine includes a conversion assembly that draws the sheet stock material therethrough and randomly crumples at least a portion of the sheet stock material. Before severing a discrete dunnage product of a desired length from the substantially continuous length of sheet stock material, the random crumpling is minimized or eliminated in an area to be cut to reduce or eliminate the production of scrap shards of sheet stock material during the cutting operation.

Abstract: A dunnage conversion machine for converting an expandable pre-slit sheet stock material into a relatively less dense dunnage product includes an improved expansion assembly that provides means for adjusting the spacing between axes of rotation of components through which the sheet stock material is drawn. The adjustability enables pre-slit sheet stock materials of differing thicknesses and/or having differing slit patterns to be fed through the expansion assembly with no or minimal compression of an expanded dunnage product, jamming in the conversion machine, bunching, and/or tearing of the pre-slit sheet stock material or expanded dunnage product resulting from expansion of the pre-slit sheet stock material.

Abstract: A dunnage conversion system (20) for expanding an unexpanded slit sheet stock material (23) to form an expanded dunnage product (26). The dunnage conversion system includes a converging chute (28) to inwardly gather laterally-extending edges of sheet stock material towards one another, causing random crumpling of the sheet stock material to form a modified ply. The conversion system also includes feed wheels (120) that advance the modified ply through the converging chute and pinch rollers (122) that cooperate with the feed wheels to expand the modified ply traveling between the feed wheels and the pinch rollers to form a dunnage product. The expanded dunnage product is expanded both in a longitudinal feed direction and in thickness as compared to the unexpanded slit sheet stock material, and thus is a three-dimensional product having increased volume and lower density per unit of length as compared to the unexpanded slit sheet stock material.

Abstract: A dunnage conversion machine includes a bunching assembly that randomly crumples at least two plies of sheet stock material into modified plies having a relatively thicker three-dimensional shape, and a feeding assembly that advances and connects together longitudinally-extending portions of the modified plies to form a dunnage strip. A diverter minimizes overlap of and encourages separation of lateral edges of the modified plies from one another, and a severing assembly severs distinct dunnage products from the strip. An exemplary resultant dunnage product includes two or more plies of crumpled sheet material interconnected along a longitudinally-extending portion having interconnected overlapped portions of each of the plies and a longitudinally-extending line of connection.

Abstract: A dunnage conversion system includes a machine for converting a stock material into a strip of relatively lower-density dunnage, a coiling mechanism for winding the strip into a coil, a taping mechanism for automatically securing a trailing end of the strip to the coil, and a coil ejecting mechanism for automatically removing the coil from the coiling mechanism. The taping mechanism includes a guide surface between an outlet of the machine and the coiling mechanism to guide the strip to the coiling mechanism and to guide tape for engagement with a trailing end of the strip and to secure the trailing end of the strip to the coil. The coil ejecting mechanism includes a lever arm that pivots to push the completed coil off the coiling mechanism.

Abstract: An unpowered, manually operable apparatus for dispensing cushioning wrap material drawn concurrently from a roll of separator material and a self-contained cartridge that includes a roll of expandable sheet material. The rolls are supported on a stand for rotation about respective parallel, spaced-apart axes. In addition to the roll, the cartridge includes a tensioning assembly and support panels that abut respective ends of the roll. The tensioning assembly and the support panels cooperate with the stand to control rotational resistance of the roll. The rotational resistance causes the expandable sheet material to expand in length and thickness as it is manually pulled from the stand with the separator material, and support surfaces on the stand hold the cartridge and the separator roll in position. When the cartridge containing the expandable sheet material is depleted, the cartridge is readily removed and replaced.

Abstract: An apparatus (10) for converting a slit-sheet stock material (16) into an expanded dunnage product (12) includes a housing (20), a pair of rollers (22, 24) within the housing extending widthwise across a path of the sheet material, and a plurality of guide strips (90) extending from an upstream side of the pair of rollers to a downstream side of the pair of rollers at a plurality of locations spaced across the width of the path. The guide strips guide the sheet material between and around the rollers. Exemplary rollers have a plurality of grooves spaced across the width of the path, and the guide strips are received in respective grooves. The guide strips may be connected by a crossbar to form a guide member.

Abstract: A packaging method includes the steps of (a) detecting whether a height (104) of contents (105) in a container (106) exceeds a predetermined height (112), and (b) indicating how much dunnage to dispense based on predetermined criteria, including whether a detected height exceeds a predetermined height that is less than a height of the container. The indicating step includes indicating a quantity of dunnage to dispense selected from a plurality of predetermined quantities of dunnage. If no detected height is greater than the predetermined height, the indicating step includes indicating that a regular amount of dunnage should be dispensed. And if a detected height is greater than the predetermined height, the indicating step includes indicating that either zero or less than the regular amount of dunnage should be dispensed. The detecting step also can include detecting whether any contents in the container have a height above the height of the container.

Abstract: A cutting mechanism is provided for a dunnage conversion machine 10 that selectively cuts dunnage sheet stock drawable through the cutting mechanism. The cutting mechanism includes a frame and a pair of opposed cutting blades through which the sheet stock is drawable. The cutting blades include a driven blade and a biased blade, each supported relative to the frame for movement into and out of contact with one another. The driven blade is movable towards the biased blade to cut the sheet stock. The biased blade is biased against movement away from the driven blade to allow for self-adjustability to counter wear of one or both of the opposed blades. Contact of the opposed blades with one another causes the biased blade to be deflected away from the driven blade.

Abstract: A stock supply assembly for a dunnage conversion machine includes a stock material support having a support structure, such as a shelf for a stack of fan-folded sheet stock material. The stock supply assembly is rotatable between a relatively lower loading position and a relatively higher operating position vertically displaced relative to the loading position.

Abstract: A stock supply assembly for a dunnage conversion machine includes a stock material support having a support structure, such as a shelf for a stack of fan-folded sheet stock material. The shelf is movable between a relatively lower loading position and a relatively higher operating position vertically displaced relative to the loading position. In the process, the support structure maintains a consistent orientation as the support structure moves between the loading position and the operating position.

Abstract: A supply of stock material for a dunnage conversion machine includes two plies of sheet stock material wound into a roll or fan-folded into a stack. Each ply has disposed on a corresponding leading or trailing end thereof an adhesive layer and a removable release liner covering the adhesive layer. When applied to a leading end of the supply, the adhesive layer is applied to opposing, outwardly-facing surfaces of the respective plies. When a supply of stock material is almost spent, the operator removes the release liners from both plies to expose respective adhesive layers, and then interposes the leading end of a new supply between the plies of the trailing end of the almost-spent supply and presses the layers together to attach the plies of the new supply to respective plies of the almost-spent supply, for conversion into dunnage.

Abstract: A dunnage production system for producing coiled strips of dunnage includes a supply of strip-like dunnage, a coiler adjacent the supply and rotatable about a coiling axis for coiling a strip of the strip-like dunnage into a coil having a coiled configuration, and a tube aligned with the coiling axis. The tube has an internal diameter sized to receive the coil from the coiler in a discharge direction parallel to the coiling axis. The tube is capable of holding at least one coil in its coiled configuration until it is removed from the tube.

Abstract: A machine for converting a sheet stock material into a relatively less dense dunnage product includes both (a) a helical pre-form assembly having a cylindrical mandrel with a longitudinal axis and a guide member for guiding the sheet stock material from a supply thereof into a helical path along and around the mandrel so as to form a helical pre-form that rotates around the longitudinal axis and advances parallel to the longitudinal axis; and (b) a restriction in the path of the pre-form that slows the advance and rotation of the pre-form past the restriction, the restriction causing the pre-form to retard longitudinal advancement, to twist upon itself, and to permanently deform as it moves past the restriction, thereby longitudinally and helically crumpling the pre-form.

Abstract: A jam-sensing method for a dunnage conversion machine includes the following steps: (a) converting a stock material into a relatively less dense dunnage material having characteristics that vary along the length of the dunnage material; (b) sensing the characteristics of the dunnage material; (c) generating a signal that varies as a function of the sensed characteristics; (d) monitoring the generated signal over time; and (e) generating a control signal when variation in the generated signal within a predetermined period is less than a predetermined amount, which would indicate a lack of movement of the material. This control signal can used to shut down the conversion process, thereby minimizing the extent of the jam condition.