Abstract: A dunnage conversion machine includes a frame, a supply support coupled to the frame for supporting a supply of expandable sheet stock material, and a pair of opposed expansion members rotatably coupled to the frame for rotation about respective axes. The expandable sheet stock material is gripped between the expansion members while it is drawn between the expansion members. Tension provided between a downstream pulling force downstream of the expansion members and the gripping force of the expansion members causes expansion of the expandable sheet stock material. Portions of the expansion members are periodically recessed to provide more uniform expansion of the expandable sheet stock material while reducing or altogether preventing jamming of expanding sheet stock material between the expansion members or tearing of the expanding sheet stock material adjacent the expansion members.

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 (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 method of converting a supply of sheet stock into a relatively less dense dunnage product, including the following steps of (i) providing a stack of fan-folded sheet material having fold lines parallel to a width dimension; and (ii) drawing sheet stock material from the stack in a direction parallel to the width dimension.

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 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 method of loading a stack of sheet stock material for use by a dunnage conversion machine, includes the following steps: (i) providing first and second stacks, the second stack being protected by a carrier having a central portion and longitudinally-spaced extensions that bound a central portion, the extensions and the central portion being joined along a weakened area defining a tear line, the central portion and the longitudinally-spaced extensions forming a planar bottom panel and a planar side panel, each panel extending substantially the length of the stack, and at a right angle to each other about a fold line over a bottom and an adjacent side of the stack, and one or more bale ties longitudinally inwardly of the tear lines holding the carrier to the stack; (ii) removing the extensions from the carrier; (iii) setting the second stack on top of the first stack; and (iv) removing the bale ties and the carrier, whereby an adhesive bonds the top page of the first stack to the bottom page of the second sta

Abstract: A machine for converting a sheet stock material into a dunnage product includes a conversion assembly for converting sheet stock material into a dunnage product as the sheet stock material travels along a path from an upstream end of the conversion assembly to a downstream end of the conversion assembly. The machine further includes a transversely extending guide over which the stock material passes for guided entry into the upstream end of the conversion assembly. The guide is rotatable such that the transverse extent of the guide can be moved between a plurality of relatively rotated orientations to guide the sheet stock material from different sides of the conversion assembly.

Abstract: A machine for converting a sheet stock material into a dunnage product includes a conversion assembly for converting sheet stock material into a dunnage product as the sheet stock material travels along a path from an upstream end of the conversion assembly to a downstream end of the conversion assembly. The machine further includes a transversely extending guide over which the stock material passes for guided entry into the upstream end of the conversion assembly. The guide is rotatable such that the transverse extent of the guide can be moved between a plurality of relatively rotated orientations to guide the sheet stock material from different sides of the conversion assembly.

Abstract: A system (10) for automatically dispensing a strip of dunnage to a container (14) includes a dispenser (12) having an outlet (92) from which the dispenser can feed a length of a strip of dunnage lengthwise, a container support (36) for supporting a container (14) thereon, and a pusher device (114) at the outlet (92) for pushing, more particularly propelling, a trailing end of the strip of dunnage from the outlet (92) toward the container support (36). The outlet (92) is aligned with the container support (36). Thus the outlet (92) is positioned relative to a container (14) such that the strip will curl or fold back and forth upon itself within the confines of the container (14) as it is being fed from the outlet (92). A container closer (120, 130 and 32) automatically closes the flaps (80 and 82) of the container (14).

Abstract: A method for making an insulating dunnage product (10) includes the steps of (a) permanently deforming at least one non-planar interior layer (12) that includes a paper sheet to form a plurality of air pockets (14), (b) surrounding the at least one interior layer (12) on all four sides and over the top and bottom sides of the at least one interior layer (12) with at least one outer layer (16) of sheet material and (c) peripherally sealing the at least one outer layer (16) to capture the at least one interior layer (12) therein such that the interior layer (12) has major portions that are free to shift relative to adjacent portions of the at least one outer layer (16).

Abstract: A packaging system (10) includes a supply (12) of stock material (14) having a cohesive on a surface thereof and an apparatus (16) for converting the stock material (14) into a packaging product (20). The apparatus (16) includes at least one crumpling assembly (22) that can advance stock material (14) from the supply (12) and can cause the stock material (14) to randomly crumple. The apparatus (16) also includes a joining assembly (24) that can bring the crumpled stock material (26) together with uncrumpled stock material (28). The crumpled stock material (26) and the uncrumpled stock material (28) each have a cohesive on at least a portion of mutually facing surfaces such that the cohesive portions on those surfaces bond together when they come into contact with each other, thereby securing the crumpled stock material (26) to the uncrumpled stock material (28).

Abstract: An improved packaging system (10) includes a packaging line that guides containers in a downstream direction, a sensor (12) that can identify a dimension of a container on the packaging line, a dunnage dispenser (14) on the packaging line downstream of the sensor to dispense dunnage to a void volume in a container, and a container closer (16) downstream of the dunnage dispenser (14) to close containers on the packaging line downstream of the dunnage dispenser. The container closer (16) includes an adjustable member (20), and is in communication with the sensor to (12) adjust the adjustable member (20) based on the identified dimension of the container. The system thus includes a way to identify the size of the container before the container reaches the container closer. The container closer can adjust for the container's size before the container arrives, speeding up the container closing operation.

Abstract: A method of loading a stack of sheet stock material for use by a dunnage conversion machine, includes the following steps: (i) providing first and second stacks, the second stack being protected by a carrier having a central portion and longitudinally-spaced extensions that bound a central portion, the extensions and the central portion being joined along a weakened area defining a tear line, the central portion and the longitudinally-spaced extensions forming a planar bottom panel and a planar side panel, each panel extending substantially the length of the stack, and at a right angle to each other about a fold line over a bottom and an adjacent side of the stack, and one or more bale ties longitudinally inwardly of the tear lines holding the carrier to the stack; (ii) removing the extensions from the carrier; (iii) setting the second stack on top of the first stack; and (iv) removing the bale ties and the carrier, whereby an adhesive bonds the top page of the first stack to the bottom page of the second sta

Abstract: A method of converting a supply of sheet stock into a relatively less dense dunnage product, including the following steps of (i) providing a stack of fan-folded sheet material having fold lines parallel to a width dimension; and (ii) drawing sheet stock material from the stack in a direction parallel to the width dimension.

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 motor-free dunnage conversion system for converting a sheet stock material into a relatively less dense dunnage includes a container having a wall with an opening therethrough, a supply of sheet stock material within the container, and a forming member. The forming member has converging sidewalls that define a passage alignable with the opening in the wall. The forming member is a converging chute having a relatively larger inlet spaced from the outlet, which is relatively smaller than the inlet. The forming member functions to crumple the sheet stock material as a packer draws the sheet stock material through the forming member to form a crumpled strip of dunnage. The forming member has a dimension that is larger than a corresponding dimension of the opening to keep the forming member from escaping the container as the packer pulls the stock material through the forming member.

Abstract: A machine for converting a sheet stock material into a dunnage product includes a conversion assembly for converting sheet stock material into a dunnage product as the sheet stock material travels along a path from an upstream end of the conversion assembly to a downstream end of the conversion assembly. The machine further includes a transversely extending guide over which the stock material passes for guided entry into the upstream end of the conversion assembly. The guide is rotatable such that the transverse extent of the guide can be moved between a plurality of relatively rotated orientations to guide the sheet stock material from different sides of the conversion assembly.

Abstract: A self-contained dunnage system includes a box sized to receive a supply of sheet stock material with minimal or no empty space when the box is closed. The box has one or more flaps that are movable between a generally planar closed position where the flaps cooperate to close the box and an inclined operating position displaced from the closed position. In the operating position, the ends of the flaps define a dispensing outlet spaced from an open side of the box defined by the side wall or walls of the box. The dispensing outlet is smaller than the open side of the box such that as the sheet material is pulled from the box and through the outlet, the inclined flaps act as a forming member that inwardly gathers the sheet material, causing it to crumple as it is withdrawn from the box.