Abstract: An apparatus for manufacturing dunnage including a plurality of rollers for pulling a web of material through the machine, a nozzle with at least one port through which gas or liquid flows, a plurality of ceramic elements in opposing positions such that the web of material can pass between the plurality of ceramic elements. A heating element is routed through each of the plurality of ceramic elements such that heat will radiate through openings in the top surfaces of the ceramic elements that will melt the portion of the material that is passing between the opposing ceramic elements. The apparatus may be equipped to manufacture multiple pieces of dunnage simultaneously.

Abstract: A system for creating and dispensing cushioning dunnage includes a plurality of material shaping members to convert a sheet stock material into a continuous strip of cushioning product. The shaping members include a constant-entry roller assembly having at least two tapered rollers supported end to end for rotation about respective ones of first and second axes arranged at an obtuse angle whose aspect faces a circumferential side of the rollers that first engages sheet stock material traveling over the rollers from a supply roll of the material. The tapered rollers present material engaging surfaces on an imaginary material conversion line transverse to the travel direction of the material where the material first engages the rollers for more precise and consistent control of alignment of the stock material. The roller assembly has free ends over which the sheet stock material can be folded to reduce the width of the material traveling over the rollers.

Abstract: The present subject matter relates generally to an apparatus for crumpling paper substrates. Specifically, the system provides for the crumpling of paper substrates to form fill material to be utilized in product packaging to fill void space and/or to wrap around products thereby allowing for safe transport of the products. The apparatus includes a feeder for feeding sheeting material, a first roller connected to a drive mechanism, a second roller disposed adjacent said first roller wherein said sheeting material travels between the first roller and the second roller and further wherein the second roller pushes said sheeting material against said first roller to engage the sheeting material with the first roller, and a third roller connected to the drive mechanism for directing said sheeting material out of said apparatus.

Abstract: This invention forms a loose fill packing material comprising clean, elongated strips of paper formed from corrugated cardboard having internal fluting formatted to expand in height, improving the ability of the strips to lattice. A vertical slitter divides cardboard into blanks of a predetermined width generally with the grain of corrugation. The blanks are fed into a shredding device that cuts the blanks with a scissor motion across the width of the blank. The strips pass onto a cleated perforated conveyor and into an enclosed suction housing. Inside the suction housing is a vortex box enhancing air flow for cleaning the strips. Strips are centered on the conveyor. The strips move from the conveyor to an angled, vibrating sifter plate into a collector. Strips are sprayed with a liquid material having microbicidal, sanitizing, insect repellant, disinfectant and/or deodorizing properties.

Abstract: A tabletop converter has a conversion assembly that inwardly gathers and crumples a stock material to form a strip of dunnage. The conversion assembly includes a feeding assembly that moves the stock material and a controller that controls the feeding assembly to operate in both a forward direction and a reverse direction. To automatically separate a discrete dunnage product from the strip, a holder grabs and holds the strip of dunnage at a holding location downstream of the feeding assembly. The feeding assembly then operates in a reverse direction and urges the strip away from the holding location. This causes the strip to separate at or between the holding location and the feeding assembly, leaving a discrete dunnage product ready for use. The converter is mounted to a stand that allows the converter to rotate relative to part of the stand about both a horizontal axis and a vertical axis.

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 dunnage conversion machine is characterized by a forming assembly which causes lateral edge portions of a substantially continuous sheet stock material to crumple and to fold upon themselves, leaving an unfolded central portion between the laterally spaced apart folded portions. The layers of sheet stock material in the folded portions are fixed by a feeding/fixing assembly having two pairs of laterally spaced feed assemblies to form a dunnage product which does not come apart as it is manipulated. A severing assembly severs discrete dunnage products from the continuous strip of dunnage.

Abstract: A system for creating and dispensing cushioning dunnage is small and permits flexible installation configuration options for a single or multiple packing stations. A compact apparatus of the system is capable of being pivotally mounted as a unit on a stand and includes a motor and a material feeding arrangement driven by the motor for pulling material from a supply roll of the material supported on a stand of the system, and feeding it through the apparatus. A plurality of material shaping members upstream of the feeding arrangement shape the material in the apparatus to convert it into a continuous strip of cushioning product.

Abstract: A system, and associated components and methodology, that provides for automatic determination and supply of an amount of dunnage to fill the void left in a container in which one or more objects have been placed. The system comprises a dunnage dispenser which is operable to dispense a controlled amount of a dunnage, a container scanner, and a logic device. The container scanner includes a height sensor for sensing a height characteristic of a container, a width sensor for sensing a width characteristic of the container, and a contour sensor for sensing a contour characteristic of the objects in the container. The logic device can (1) process sensed characteristic information from the height sensor, width sensor and contour sensor, (2) determine the amount of dunnage needed to fill the void not occupied by the objects, and (3) command the dunnage dispenser to dispense the determined amount of dunnage.

Abstract: A method, apparatus and system for making cushioning product, and a roll tensioner therefor apply frictional resistance to the periphery of a roll of material to be converted into cushioning product with at least one roll support member which supports the roll in addition to applying frictional resistance to rotation. Efficient operation is attained automatically in that the frictional resistance applied and also the pulling profile exerted on the material during unwinding of the roll are changed as a function of weight and/or other characteristics of the roll of material to be converted into cushioning product.

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 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 packing material has a plurality of separable layers of pliable material. Each layer has a region containing a plurality of domes in a pattern extending in two directions. The plurality of domes are nested together in the region. The plurality of domes each have a top, a base and a side extending from the top to the base at an angle of divergence exceeding 10°. The plurality of domes have a dome height of at least ? inch. Adjacently nested pairs of the domes have between them an overhead gap no greater than 10% of the dome height. The plurality of separable layers with the plurality of domes can be separated and disoriented to occupy a larger volume. These separable layers may be discrete layers, pleats in a web, or sections of a web.

Abstract: The apparatus for cutting cushion-like packaging material from a web-like supply of material having at least two layers has a base plate (1), a fixed knife (2) and a movable knife (3), which are arranged above the base plate (1), as well as a drive arrangement for the movable knife. The base plate (1) is connected to a shaft (6) for feeding the packaging material. The drive mechanism is connected drive-wise to the movable knife. A counter-holder (5) with a support surface (22) to support the packaging material during cutting and a means for holding (23) the counter-holder (5) above the fixed knife (2) are provided, the whole being such that the support surface (22) is flush with the cutting edge (17) of the fixed knife. By means of the counter-holder, the cutting is improved in an advantageous manner and paper jams are avoided.

Abstract: An inflatable cushioning article is made from a multilayer film having a seal layer, a gas barrier layer, and a tie layer adhering the seal layer to the gas barrier layer. The cushioning article has a plurality of inflatable chambers, with each of the chambers having a plurality of cells connected in series to one another via inflation channels. Although the inflatable article can be made from relatively thin films, the article exhibits a relatively high burst pressure and can be inflated to, for example 3 psi, and withstand conditions such as 140° F. and high altitude, without film delamination, seal failure, or film rupture. Preferably, the tie layer comprises an anhydride modified polyolefin having an anhydride content of at least 150 ppm.

Abstract: An inflatable web, and method and apparatus for inflating the web, which generally includes two sheets having inner surfaces sealed to each other in a pattern defining a series of inflatable chambers of predetermined length, each of the chambers having at least one change in width over their length; an inflation port located at a proximal end of each chamber, the inflation ports being formed by intermittent seals between the sheets; and longitudinal flanges formed by a portion of each of the sheets that extend beyond the inflation ports and intermittent seals.

Abstract: A method of determining a total amount of stock material passing through a cushioning conversion machine over a period of time during which a plurality of three-dimensional cushioning products are made. The method includes the acts of providing a sheet stock material; converting the sheet stock material into a plurality of the three-dimensional cushioning products with the cushioning conversion machine during the period of time; monitoring the passage of stock material through the cushioning conversion machine during the period of time; storing in a computer memory information regarding the total amount of stock material that passed through the cushioning conversion machine during the period of time; and retrieving the stored information, the retrieved stored information providing an indication of the total amount of stock material that passed through the cushioning conversion machine during the period of time.

Abstract: A tabletop converter has a conversion assembly that inwardly gathers and crumples a stock material to form a strip of dunnage. The conversion assembly includes a feeding assembly that moves the stock material and a controller that controls the feeding assembly to operate in both a forward direction and a reverse direction. To automatically separate a discrete dunnage product from the strip, a holder grabs and holds the strip of dunnage at a holding location downstream of the feeding assembly. The feeding assembly then operates in a reverse direction and urges the strip away from the holding location. This causes the strip to separate at or between the holding location and the feeding assembly, leaving a discrete dunnage product ready for use. The converter is mounted to a stand that allows the converter to rotate relative to part of the stand about both a horizontal axis and a vertical axis.

Abstract: A system for creating and dispensing cushioning dunnage includes a plurality of material shaping members to convert a sheet stock material into a continuous strip of cushioning product. The shaping members include a constant-entry roller assembly having at least two tapered rollers supported end to end for rotation about respective ones of first and second axes arranged at an obtuse angle whose aspect faces a circumferential side of the rollers that first engages sheet stock material traveling over the rollers from a supply roll of the material. The tapered rollers present material engaging surfaces on an imaginary material conversion line transverse to the travel direction of the material where the material first engages the rollers for more precise and consistent control of alignment of the stock material. The roller assembly has free ends over which the sheet stock material can be folded to reduce the width of the material traveling over the rollers.

Abstract: A system for creating and dispensing cushioning dunnage is small and permits flexible installation configuration options for a single or multiple packing stations. A compact apparatus of the system is capable of being pivotally mounted as a unit on a stand and includes a motor and a material feeding arrangement driven by the motor for pulling material from a supply roll of the material supported on a stand of the system, and feeding it through the apparatus. A plurality of material shaping members upstream of the feeding arrangement shape the material in the apparatus to convert it into a continuous strip of cushioning product.

Abstract: A dunnage conversion machine for converting stock material into a dunnage product includes a forming assembly and a pulling assembly. The pulling assembly includes at least two grippers movable together through a transfer region in opposition to one another and cooperative to grip therebetween the dunnage strip for advancing the dunnage strip through the transfer region, and at least one of the grippers including an aperture operative to gather and laterally capture therein the dunnage strip as the grippers move through the transfer region. Also disclosed is a severing assembly including a movable blade and a reciprocating actuator connected to the blade by a motion transmitting assembly that moves the blade through a full severing cycle upon a stroke of the actuator in either direction.

Abstract: A cushioning conversion machine for converting multi-ply stock material is characterized by a conversion assembly which comprises one or more assemblies and/or devices for converting multi-ply stock material into a three-dimensional cushioning product and a stock supply assembly for providing stock material to the conversion assembly. The stock supply assembly includes a stock roll holder assembly having one or more rotatable roll support members that extend transverse to the path of the stock material and engage an outer periphery of a stock roll for advancing the stock material therefrom. A connecting assembly includes a carrier pivotally mounted to a frame for urging a first rotating feed member toward and away from a second rotating feed member.

Abstract: A dunnage conversion machine is characterized by a forming assembly which causes lateral edge portions of a substantially continuous sheet stock material to crumple and to fold upon themselves, leaving an unfolded central portion between the laterally spaced apart folded portions. The layers of sheet stock material in the folded portions are fixed by a feeding/fixing assembly having two pairs of laterally spaced feed assemblies to form a dunnage product which does not come apart as it is manipulated. A severing assembly severs discrete dunnage products from the continuous strip of dunnage.

Abstract: A cushioning conversion machine and method for converting sheet stock material into a cushioning dunnage product with better control over the tension of the stock material fed into such machines for conversion into a dunnage product and better control over the dunnage product during a cutting operation to minimize the chance of a machine jam. The machine and method are characterized by a stock supply assembly that includes a plurality of constant entry guides at an upstream end of the machine for passage of respective plies of stock material thereover, a biased damper over which the multi-ply stock material can be trained before passage to constant entry guides, and a plurality of separators between the constant entry guides and the conversion assembly. Also disclosed is a severing assembly for severing the strip of cushioning to form a pad, which severing assembly includes a shutter movable with the moving blade for substantially blocking the strip path when the moving blade is in its extended position.

Abstract: A method, apparatus and system for making cushioning product, and a roll tensioner therefor apply frictional resistance to the periphery of a roll of material to be converted into cushioning product with at least one roll support member which supports the roll in addition to applying frictional resistance to rotation. Efficient operation is attained automatically in that the frictional resistance applied and also the pulling profile exerted on the material during unwinding of the roll are changed as a function of weight and/or other characteristics of the roll of material to be converted into cushioning product.

Abstract: An inflatable cushioning article is made from a multilayer film having a seal layer, a gas barrier layer, and a tie layer adhering the seal layer to the gas barrier layer. The cushioning article has a plurality of inflatable chambers, with each of the chambers having a plurality of cells connected in series to one another via inflation channels. Although the inflatable article can be made from relatively thin films, the article exhibits a relatively high burst pressure and can be inflated to, for example 3 psi, and withstand conditions such as 140° F. and high altitude, without film delamination, seal failure, or film rupture. Preferably, the tie layer comprises an anhydride modified polyolefin having an anhydride content of at least 150 ppm.

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: A process of forming dunnage is disclosed. A chain of interconnected plastic pouches (38) are fed along a path of travel to a fill and seal station (24). The pouches (38) are sequentially opened as each pouch is positioned in the fill station. Each pouch is opened by directing a flow of air through a pouch fill opening (50) to separate a face (46) from a back (48) of each such pouch and continuing the flow of air through each such opening to inflate each opened pouch. Each such inflated pouch is then sealed to create hermetically closed and inflated dunnage units (56). Novel web and dunnage units are also disclosed.

Abstract: A packing material having a plurality of domes formed therein, and methods for forming same are provided. A plurality of layers of a substrate are placed together to form a composite material with a plurality of layers, and domes are formed in the plurality of layers. The domes can be formed in more than one direction and can be of different sizes and shapes. Thereafter, the materials can be cut to desired sizes or shapes. The domes formed in the layers are nested and accordingly, the packaging material takes up a minimal amount of space after same is manufactured. This serves to minimize the expense and space requirements for storage and shipping and disposal. In use, the sheets are separated and disoriented to achieve bulk and are utilized for packing. The domes are sized, shaped and positioned to tend against re-nesting.

Abstract: Dunnage making machine and method in which a web of paper is drawn across a forming bar with curved end sections to roll the edge portions of the paper, then drawn through a first throat section to urge the rolled edge portions toward each other and cause them to gather, and thereafter through a second throat section of lesser dimension than the first to gather the central portion of the paper and further gather the edge portions. The gathered paper is then pressed with a roller to crumple it, following which the crumpled paper is perforated along a serrated tear line.

Abstract: A novel packaging wrap is used in cushioning a product for shipment and is formed from the combination of a layer of pleated sheet material, the pleated material being creased at the apices of each pleat, and a planar layer of sheet material which is adhered to, and preferably, adhesively bonded, to a pleated sheet of kraft paper. The pleated sheet material has a weight in the range from about 30 to 50 pounds and the planar sheet material is preferably tissue paper having a weight of less than about 20 pounds. The pleated sheet material preferably, has a pleat angle in the range from above 45 degrees to below 85 degrees, and most preferably the pleats have an angle of about 50 to 65 degrees. Preferably, the pleats have a height in the range from about 3 sixteenths of an inch to about one half inch, in terms of distance between top planar sheet and bottom planar sheet.

Abstract: A cottoner having a wadding section forming station, the station having: a carrier, a holder, and a feed mechanism mounted on a base in series. Moving means on the base reciprocate the a carrier toward and away from the feed mechanism. An operating controller on the base open and close the holder. The carrier has a gripper for gripping a length of wadding material to carry it from the holding means toward the feeding means when the carrier is moved toward the feed mechanism while the holder is open. The carrier releases the length of wadding material when moved away from the feed mechanism while the holder is closed to hold the length of wadding material. The cottoner includes an inserting station for inserting each section of wadding material formed at the wadding section forming station into a container. The cottoner also has a sensing station for sensing if the wadding material has been inserted, and inserted properly, into the container at the inserting station.

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 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 cushioning conversion machine having a novel former around which a sheet material is folded to form an improved cushioning product. The former has longitudinally spaced side surfaces inclined from bottom to top toward a downstream end of the machine. The side surfaces cause the obstruction of the sheet stock material upstream of the side surfaces so that the sheet material crumples in the spaces upstream of the side surfaces, thereby increasing the cushioning properties of pillow portions of the cushioning product. The former also has a centrally located base plate which minimizes crumpling in a central portion of the sheet material so that the folded over portions and the central portion can be connected to maintain more effectively the shape of the pillow portions in the resulting cushioning product. In addition, the former has a guard plate mounted above longitudinally spaced bottom edges extending laterally outwardly from the base plate and upstream from a vertical central plane.

Abstract: The present invention discloses folded corrugated materials for producing segments or strips for use as Easter grass, packing material and the like wherein the folded corrugated materials are formed of paper and polymeric film.

Abstract: A paper shredder for cutting sheet material includes a first and second blade and a sheet feeding assembly. The first blade has a cutting edge along one side thereof and the cutting edge has a non-straight profile. The second blade has a cutting edge that meshes with the cutting edge of the first blade and the first and second blades are movable relative to each other. The sheet feeding assembly moves the sheet material towards the first and second blade such that the direction of motion is generally orthogonal to each cutting edge. The cutting edge profile may have a variety of shapes, including a zig zag, a wave or a combination thereof. The paper shredder is used for making packing material that includes a plurality of pieces of shredded generally planar sheet material, each piece having two elongate outside edges with non-straight profiles.

Abstract: A dunnage conversion machine for converting stock material into a dunnage product includes a forming assembly and a pulling assembly. The pulling assembly includes at least two grippers movable together through a transfer region in opposition to one another and cooperative to grip therebetween the dunnage strip for advancing the dunnage strip through the transfer region, and at least one of the grippers including an aperture operative to gather and laterally capture therein the dunnage strip as the grippers move through the transfer region. Also disclosed is a severing assembly including a movable blade and a reciprocating actuator connected to the blade by a motion transmitting assembly that moves the blade through a full severing cycle upon a stroke of the actuator in either direction.

Abstract: A system for providing dunnage to packages as the packages are formed is disclosed. The system includes a dunnage forming machine having a work station for inflating and sealing plastic pouches to form dunnage units. An accumulator is positioned below the station for receiving and collecting such units as they are formed. The accumulator includes an outlet opening laterally offset from the station. A pair of counter rotating brushes having axes journaled in spaced relationship are mounted at the outlet. Each of the brushes includes circumferentially spaced bristle sets defining unit receiving spaces between adjacent sets. A motor drive is operably connected to the brushes for causing counter rotation. A unit volume sensor is provided for emitting a machine start signal when the volume of units in the accumulator reaches a predetermined low volume. A process for providing dunnage in packages being formed is also disclosed.

Abstract: A system for creating and dispensing cushioning dunnage is small and permits flexible installation configuration options for a single or multiple packing stations. A compact apparatus of the system is capable of being pivotally mounted as a unit on a stand and includes a motor and a material feeding arrangement driven by the motor for pulling material from a supply roll of the material supported on a stand of the system, and feeding it through the apparatus. A plurality of material shaping members upstream of the feeding arrangement shape the material in the apparatus to convert it into a continuous strip of cushioning product.

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 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 (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 packaging material comprising a plurality of cushioning members for cushioning an article in a container is provided. The cushioning members being formed by crumpling a flexible sheet of material having a plurality of slits extending through the sheet of material and into a globular configuration having a plurality of random folds, a plurality of random engaged portions, and a plurality of voids. The sheet of material has an upper surface and a lower surface with at least one of the upper surface and the lower surface having a bonding material disposed thereon such that at least a portion of the engaged portions are bondably connected thereby increasing the resiliency of the folds.

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 system for creating and dispensing cushioning dunnage is small and permits flexible installation configuration options for a single or for multiple packing stations. A compact apparatus of the system is capable of being pivotally mounted as a unit on a stand and includes a motor and a material feeding arrangement driven by the motor for pulling material from a supply roll of the material supported on a stand of the system, and feeding it through the apparatus. A plurality of material shaping members upstream of the feeding arrangement shape the material in the apparatus to convert it into a continuous strip of cushioning product. A perforator driven by the motor perforates the material at spaced locations along the length of the material to allow an operator to manually rip a desired length of cushioning product from the material being dispensed from the apparatus.

Abstract: A cushioning conversion machine and method for converting sheet stock material into a cushioning dunnage product and wherein the tension in the stock material is controlled to avoid problems associated with improper tension. A conversion assembly draws the stock material from a stock supply and converts the stock material into a strip of cushioning, and a controller controls the operation of the conversion assembly. The conversion assembly is powered by a motor and the controller controls the operation of the motor in response to a sensed parameter related to the tension in the paper. In another embodiment, a torque control is interposed between the feed motor and feed components that engage the stock material.

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.