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 conversion machine and related methodology characterized by one or more features including, inter alia, a feeding/connecting assembly which enables an operator to easily vary a characteristic, for example the density, of the cushioning product; a feeding/connecting assembly wherein input and/or output wheels or rollers thereof are made at least in part of an elastomeric or other friction enhancing material, which reduces the cost and complexity of the input and output rollers; a manual reversing mechanism that is useful, for example, for clearing paper jams; a modular arrangement of a forming assembly and feeding/connecting assembly in separate units that may be positioned remotely from one another, as may be desired for more efficient utilization of floor space; a turner bar which enables alternative positioning a stock supply roll; and a volume expanding arrangement cooperative with the feeding/connecting assembly for reducing the density of the cushioning product and increasing product yield.

Abstract: A conversion machine and related method for making a dunnage product by converting a sheet-like stock material of at least one ply into a dunnage product is characterized by a manual reversing mechanism that is useful, for example, for clearing paper jams. The conversion machine includes a housing through which the stock material passes along a path, and an assembly that advances the stock material from a source thereof along the path, crumples the stock material, and maintains the shape of the crumpled stock material to produce a strip of dunnage. This assembly includes at least one rotatable member rotatable in a first direction for engaging and advancing the stock material, a feed motor for driving a driven rotatable member in the first direction, and a crank connected to the rotatable member for enabling rotation of the driven rotatable member in a second direction opposite the first direction.

Abstract: An improved cushioning conversion machine and related methodology characterized by one or more features including, inter alia, a feeding/connecting assembly which enables an operator to easily vary a characteristic, for example, the density, of the cushioning product; a manual reversing mechanism that is useful, for example, for clearing paper jams; a modular arrangement of a forming assembly and feeding/connecting assembly in separate units that may be positioned remotely from one another, as may be desired for more efficient utilization of floor space; and a volume expanding arrangement cooperative with the feeding/connecting assembly for adjusting the density of the cushioning product and changing product yield. The features of the invention may be individually or collectively used in cushioning conversion machines of various types.

Abstract: A method and machine for making a plurality of accordion-folded strips each having a predetermined unfolded length. A sheet of material is longitudinally and transversely separated into a plurality of strips and the strips are folded into a plurality of accordion-folded strips. The method/machine are characterized by the transverse separation of the strip occurring at completion of the longitudinal separation.

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 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 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 method and machine for making a plurality of accordion-folded strips each having a predetermined unfolded length. A sheet of material is longitudinally and transversely separated into a plurality of strips and the strips are folded into a plurality of accordion-folded strips. The method/machine are characterized by the transverse separation of the strip occurring at completion of the longitudinal separation.

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 method and machine for making a plurality of accordion-folded strips each having a predetermined unfolded length. A sheet of material is longitudinally and transversely separated into a plurality of strips and the strips are folded into a plurality of accordion-folded strips. The method/machine are characterized by the transverse separation of the strip occurring at completion of the longitudinal separation.

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 conversion machine, method and product characterized by a connecting assembly that provides a mechanical interlock between overlapped portions of sheet-like stock material to prevent “unzippering” of a low density cushioning product produced by the cushioning conversion machine. The connecting assembly comprises a pair of rotatable stitching members, a first one having a plurality of radially outwardly extending projections, or teeth, around the circumference thereof, with the projections having at least two axially spaced apart segments defining a recess therebetween. The second stitching member includes at least one axial punch segment which includes a peripheral edge portion dimensioned to be received in the recess in the first stitching member during rotation of the stitching members.

Abstract: A cushioning conversion machine for converting a sheet stock material into a cushioning product. The cushioning conversion machine includes a forming assembly which forms the stock material into a three- dimensional strip and a feed assembly which feeds the stock material through the forming assembly. The forming assembly includes a chute and a forming member at least partially positioned within the chute. The forming member is attached to the chute independently of the machine's frame whereby the chute and the forming member may be assembled as a subassembly and then this subassembly mounted to the machine's frame.

Abstract: A cushioning conversion machine, method and product characterized by a connecting assembly that provides a mechanical interlock between overlapped portions of sheet-like stock material to prevent "unzippering" of a low density cushioning product produced by the cushioning conversion machine. The connecting assembly comprises a pair of rotatable stitching members, a first one having a plurality of radially outwardly extending projections, or teeth, around the circumference thereof, with the projections having at least two axially spaced apart segments defining a recess therebetween. The second stitching member includes at least one axial punch segment which includes a peripheral edge portion dimensioned to be received in the recess in the first stitching member during rotation of the stitching members.

Abstract: A novel stock roll support assembly and loading method for a cushioning conversion machine that produces dunnage product from sheet stock material supplied as a roll provides for easier loading of the stock roll onto a roll support at the upstream end of the cushioning conversion machine in certain situations, such as where the machine is located against a wall or over (or under) a conveyor, etc. The stock roll support assembly is connected to a main frame of the machine for rotatably supporting a roll of sheet stock material. The stock roll support assembly includes a stock roll support mounted to the main frame for swinging movement between an operating position and a loading position. In the operating position, the stock roll support is operative to support the stock roll adjacent the main frame, and in the loading position, the stock roll support is swung away from the main frame to facilitate loading of a stock roll thereon.

Abstract: An improved cushioning conversion machine and related methodology characterized by one or more features including, inter alia, a feeding/connecting assembly which enables an operator to easily vary a characteristic, for example, the density, of the cushioning product; a feeding/connecting assembly wherein input and/or output wheels or rollers thereof are made at least in part of an elastomeric or other friction enhancing material, which reduces the cost and complexity of the input and output rollers; a manual reversing mechanism that is useful, for example, for clearing paper jams; a modular arrangement of a forming assembly and feeding/connecting assembly in separate units that may be positioned remotely from one another, as may be desired for more efficient utilization of floor space; a turner bar which enables alternative positioning of a stock supply roll; and a volume expanding arrangement cooperative with the feeding/connecting assembly for adjusting the density of the cushioning product and changing pr

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 for converting a sheet-like stock material into a cushioning product. The machine includes a forming assembly which forms the sheet-like stock material into a three-dimensional strip of dunnage; a stock supply assembly which supplies the stock material to the forming assembly; a feed assembly which feeds the stock material through the forming assembly; and a cutting assembly which cuts the strip of dunnage into sections of a desired length. The forming assembly includes a chute having an inlet end which is outwardly flared in a trumpet-like fashion to facilitate passage of the sheet-like stock material into the chute.