Abstract: Pre-folded stock material for use in a cushioning conversion machine which converts the pre-folded stock material into a three-dimensional cushioning product. The stock material includes at least one ply having a plurality of layers at two of which are joined at a longitudinally extending fold. The stock material is preferably biodegradable, recyclable, and reusable paper and may be supplied in a roll or in a fan-folded stack.

Abstract: A cushioning conversion machine and method employing a loading assembly that eliminates the need to manually thread sheet-like stock material through a forming assembly of the machine during a loading operation. The loading assembly and associated method are characterized by cooperating feed members that are located adjacent an upstream or inlet end of a converging chute. Upon actuation of an accessible operator member, the feed members are selectively engaged to push stock material through the chute and out the exit end of the chute for engagement by a feeding/connecting assembly which is at least energized during such selective engagement.

Abstract: A pair of clutches selectively transmit power to a coining mechanism and to a cut-off mechanism in a paper converting machine. As sheet-like material is advanced through the machine, it is formed into a three dimensional strip of padding by a forming mechanism. Next the strip is coined or otherwise secured to keep its three dimensional shape by a coining mechanism. Thereafter the strip is cut into sections of the desired length by a cut-off mechanism. Advantageously, both the coining mechanism and the cut-off mechanism are powered by a single motor, then are selectively connected to the motor by a pair of clutches. The clutches may be wrap spring clutches, and the clutch controlling power to the cut-off mechanism may be a single revolution clutch.

Abstract: A cushioning dunnage conversion machine for converting sheet-like stock material, such as paper in multiply form, into cut sections of relatively low density pad-like cushioning product, and cutting assembly therefor, is provided. The machine includes a stock supply assembly, a forming assembly, a pulling/connecting assembly and a cutting assembly, all of which are mounted on a machine frame. The machine frame includes a base plate having an upstream end and a downstream end, a first end plate extending generally perpendicular from the upstream end of the end plate and a second end plate extending generally perpendicular from the downstream end of the base plate.

Abstract: A cushioning conversion machine for converting a sheet-like stock material into a dunnage product includes a frame having an upstream end and a downstream end, conversion assemblies, mounted on the frame, which convert the sheet-like stock material into a continuous strip of a dunnage product, a feeding assembly, mounted on the frame, for feeding the stock material through the conversion assemblies, a cutting assembly, mounted on the frame downstream of the conversion assemblies, which cuts the continuous strip of dunnage into a section of a desired length, a probe for determining the packaging requirements of a particular container, and a controller which controls the feeding and cutting assemblies to produce the required sections of dunnage product for the container as determined by the probe.

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 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 cushioning conversion machine and method for converting sheet-like stock material into a cushioning product without the use of a conventional forming device, thereby enabling a substantial reduction in the size of the machine. The machine and method are characterized by the use of a web of flat-folded sheet-like stock material of one or more plies and an expanding device which is operative to open up, or "expand", the flat folded stock material before passage through a crumpling and/or connecting device which also preferably functions to advance the stock material through the machine. The invention also provides a flat folded web of stock supply including at least one ply of sheet-like stock material having portions thereof folded upon themselves along the length of the stock material.

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 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 machine and method for converting stock material into a cushioning product, characterized by a manual feed mechanism or assembly. The machine includes a shaping member over which the stock material is drawn to form the stock material into a three-dimensional shape and the manual feed mechanism draws the stock material over the shaping member. The manual feed mechanism may include a rotatable member for engaging and advancing the stock material, and an operator member mounted for reciprocating movement and operatively connected to the rotatable member.

Abstract: A machine and method for making folded strips, which machine and method are characterized by features that enable a reduction in the size, weight and cost of the machine. The machine and method comprises a housing having first and second housing sections, a longitudinal severing assembly for longitudinally severing the sheet stock material into a plurality of strips, and a folding device downstream of the longitudinal severing assembly and operative to cause back and forth folding of the strips to produce accordion-folded strips having substantially uniform adjacent opposite folds. The longitudinal severing assembly includes first and second slitting members respectively carried in the first and second housing sections, and the first and second housing sections are separable whereby the housing is openable to maintain and repair the machine. The slitting members include a shaft and an array of slitting discs carried on the shaft for rotation therewith.

Abstract: A cushioning conversion machine, and method of using such a machine, in which stock material is converted into a cushioning product. The machine and method are characterized by providing stock material having information encoded thereon and then retrieving the encoded information from the stock material for machine control, diagnostic, inventory, and other purposes.

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.

Abstract: A cushioning conversion machine (10) comprises a frame (36), conversion assemblies (50, 52, 54, 56) which convert a stock material into a cushioning product, and a length measuring device (12) which determines the length of the cushioning product as it is being produced. The conversion assemblies include a rotating assembly (54) and the angular movement of this assembly directly corresponds to the length of the cushioning product. The length measuring device (12) is positioned to monitor the angular movement of the rotating conversion assembly (54) and thus the length of the cushioning product. In the preferred embodiment, the rotating conversion assembly (54) is a gear assembly.

Abstract: A cushioning conversion machine for converting a sheet-like stock material into a dunnage product includes a frame having an upstream end and a downstream end, conversion assemblies, mounted on the frame, which convert the sheet-like stock material into a continuous strip of a dunnage product, a feeding assembly, mounted on the frame, for feeding the stock material through the conversion assemblies, a cutting assembly, mounted on the frame downstream of the conversion assemblies, which cuts the continuous strip of dunnage into a section of a desired length, a probe for determining the packaging requirements of a particular container, and a controller which controls the feeding and cutting assemblies to produce the required sections of dunnage product for the container as determined by the probe.

Abstract: A cushioning conversion machine for converting a sheet-like stock material into a cushioning product. The machine includes a manual cutting assembly having a blade and a handle which moves the blade between a first position whereat a strip of dunnage may advance through a cutting zone and a second position whereat the strip of dunnage will be cut in the cutting zone. The cutting zone is defined by a housing which encloses the blade of the cutting assembly. The handle of the cutting assembly is positioned outside of the housing for manual manipulation.

Abstract: An automated cushioning producing and filling system includes a cushioning conversion machine which converts stock paper into cut pads of a selected length and transports the pads to a staging location, a pad sensor for sensing the presence of a pad in the staging location, a box transporting system for transporting a box from a remote location to a filling location, a box sensor for sensing the presence of a box in the filling location, a bar code reader for reading a bar code from the box indicative of the packaging requirements of the box when the box sensor has sensed the presence of a box in the filling location, a pad transferring apparatus for transferring a pad from the staging location to the box when the pad sensor has sensed the presence of a pad in the staging area, and a system controller for determining the box packaging requirements from the code read by the bar code reader and instructing the cushioning conversion machine to produce pads in accordance with the packaging requirements for the bo

Abstract: A cushioning conversion machine and method employing a loading assembly that eliminates the need to manually thread sheet-like stock material through a forming assembly of the machine during a loading operation. The loading assembly and associated method are characterized by cooperating feed members that are located adjacent an upstream or inlet end of a converging chute. Upon actuation of an accessible operator member, the feed members are selectively engaged to push stock material through the chute and out the exit end of the chute for engagement by a feeding/connecting assembly which is at least energized during such selective engagement.

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 machine's housing at least partially encloses the forming assembly, the feed assembly, and the cutting assembly. The machine further comprises a stand including a support to which the housing is mounted and a base extending from the support to which the stock supply assembly is mounted.