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 sheet-like stock material into a cushioning product. The machine includes a forming assembly which inwardly crumples the lateral edges of the sheet-like stock material to form a dunnage strip, a stock supply assembly which supplies the stock material to the forming assembly, and a feed assembly which feeds the stock material to the forming assembly. The method includes the steps of withdrawing a section of stock material from a continuous web and forming the stock material into a dunnage strip. The cushioning conversion machine and method are characterized by an embossing device or step which embosses the stock material.

Abstract: A machine for manufacturing a cushioning product starting from a multi-ply stock (R) material or the like includes a frame (12) having a housing (14) with an exit opening, a stock supply supported by the frame, a forming assembly (28) causing the lateral edges of the stock material to roll inwardly to form a continuous strip (36) having lateral pillow-like portions and a central band, a gear assembly (34) for feeding the stock material through the forming assembly and out the exit opening, a cutting assembly (26) intermediate the gear assembly and the exit opening for cutting a determined length of the continuous strip to produce a cushioning product and, an access assembly (46) for permitting the cushioning product to be fed therethrough and inhibiting access to the cutting assembly from outside the housing.

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 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 method and apparatus for manufacturing paper cushioning members in which work paper is inserted between a pair of intermittent-cutting roller members to process multiple rows of thin bands with link portion. Waste-collecting members are provided at a discharge side of the rollers to separate the work paper from the roller members and to feed the processed work paper into a wave-forming guide. The wave-forming guide includes an upper pressing member that rotates about a hinge positioned at an end nearest to the discharge side of the rollers and a counterweight positioned at a distal end of said upper pressing member such that the upper pressing member is biased toward the interior of the wave-forming guide. The wave-forming guide is designed to forcibly compress the processed work paper into finely crumpled thin bands and to discharge the crumpled thin bands in a wavy form.

Abstract: A cushioning conversion machine for converting a sheet-like stock material into cushioning products is provided. The machine includes an outlet extension which forms a continuous passageway for the cushioning products from the machine outlet to an appropriate exit location. The outlet extension is coupled to the outlet in such a manner that it is selectively adjustable relative to the outlet to provide for a plurality of exit locations for the cushioning products.

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 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: 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 stock material for use with a cushioning conversion machine is provided. The stock material includes a plurality of superimposed plies of a sheet-like material which are fan-folded into a rectangonal stack. The superimposed plies include a series of alternating folds which each create superimposed creases through the plies. The alternating folds together form a sequence of rectangular pages which are piled accordion-style one on top of the other to form the rectangonal stack.

Abstract: In a machine for making packaging material, paper is pulled off a roll by two pairs of spaced rubber nip rollers, the lower ones of which rollers are driven. The edges of the paper roll over as the paper passes through the former and the rolled paper is pushed into a pair of meshing gear wheels in order to hold the rolled dunnage together loosely. A pair of blades cut the dunnage to the required length after it has passed through the gear wheels.

Abstract: The present invention relates of a method and apparatus for making an improved resilient packing material by forming, resiliently folding and crimping shredded strips of moistened paper material into an improved interlocking, bulk, packaging material. The method and apparatus includes a wetting or dampening system which can be selectively varied to regulate the moisture content of moistened paper material.

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 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.

Abstract: A diagnostic system for performing real time diagnostics on a cushioning conversion machine includes a machine resident controller for controlling and monitoring operation of the cushioning conversion machine, a remote processor for performing diagnostic functions based on information retrieved from a cushioning conversion machine, and a communication device for facilitating real time communication between the machine resident controller and the remote processor.

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: In combination, a dispensing table (10) and a cushioning conversion machine (12) which is slidably mounted to the table (10). The table (10) includes a substantially horizontal work platform (14) and the machine (12) is situated below the platform (14). The cushioning conversion machine (10) includes conversion assemblies (50, 52, 54, 56, 58) which convert stock material (S) into a cushioning product (P). The cushioning conversion machine (12) is slidable to an operating position whereat the cushioning product (P) is deposited on the work platform (14) during operation of the machine. Preferably, the machine (12) is also slidable to an upstream position whereat its upstream portion projects outwardly from the table (10) and loading and threading procedures can be easily performed.

Abstract: A streamer is disclosed which includes at least one strip of plastic film having a silvered layer and a lacquered coating containing a lubricant. In one embodiment, the strip includes a plurality of individual strips wound together with overlapping ends such that the individual strips separate into multiple pieces as the streamer flies through the air. In another embodiment, a lubricant is disposed between each wound layer of film such that the outermost layer may be slid off the streamer without the provision of a tab.

Abstract: A cushioning conversion machine, converting method and dunnage product characterized by a novel connecting assembly which provides a unique interlock between overlapped portions of sheet-like stock material forming a dunnage product to prevent "unzippering" of the product. The connecting assembly includes a pair of loosely meshed stitching wheels, a first one of the stitching wheels having a plurality of radial projections protruding from a radially outer circumferential surface thereof, and a second one of the stitching wheels including a plurality of recesses for receiving the radial projections in meshed relationship upon rotation of the stitching wheels.

Abstract: A cushioning conversion machine for converting stock material into a continuous strip of a cushioning product. The machine includes a stock-preparing assembly which prepares the stock material; a stock-shaping assembly which shapes the prepared stock material into a continuous strip having a pillow-like portion and at least one tab portion projecting therefrom; and a tab-connecting assembly which connects the tab portion of the continuous strip whereby the pillow-like portion will maintain its pillow-like geometry.

Abstract: A cushioning conversion machine for converting stock material into a continuous strip of a cushioning product. The machine includes a stock-preparing assembly which prepares the stock material; a stock-shaping assembly which shapes the prepared stock material into a continuous strip having a pillow-like portion and at least one tab portion projecting therefrom; and a tab-connecting assembly which connects the tab portion of the continuous strip whereby the pillow-like portion will maintain its pillow-like geometry.

Abstract: A redundant automated cushioning producing and dispensing system includes a plurality of spaced cushioning conversion machines which convert stock paper into pads of a selected length, each cushioning conversion machine including a controller for controlling operation of the machine and communicating with another machine, a pad dispenser, and a sensor for determining when the amount of stock paper is less than a predetermined amount, a conveyor extending between the plurality of cushioning conversion machines for conveying a container into which a pad is to be dispensed, and at least one container sensor for providing information to at least one controller from which the controller can determine whether a pad has been dispensed into a container whereby the controllers cooperate to selectively switch operation of the cushioning conversion machine from an active state to an inactive state in accordance with information received from the stock supply sensors.

Abstract: A cushioning conversion machine and method for converting multiple layers of sheet-like stock material into a cushioning product are characterized by a forming assembly which shapes plural layers of the stock material into a continuous three dimensional strip of dunnage having central portions and overlapped edge portions, a connecting assembly downstream of the forming assembly for connecting the overlapped lateral edge portions of the layers separately from central portions of the layers, and a guide which directs the central portions of the layers away from connecting assembly to prevent the central portions from passing through the connecting assembly.

Abstract: A loading device and method for loading sheet-like stock material in a cushioning conversion machine. The loading device comprises an elongated threading member having an end portion dimensioned to pass through the stock material path of the cushioning conversion machine and at least one clip or other attachment device proximate an end of the threading member for attaching the stock material to the threading member. After attaching a leading end of the stock material to the loading device, the loading device is advanced through the cushioning conversion machine until the leading end of the stock material exits the downstream end of the machine.

Abstract: A cushioning conversion system includes a cushioning conversion machine which converts stock paper into cut pads, a conveyor system positioned to receive a pad produced by the cushioning conversion machine and to move the pad to a staging area, the staging area including a sensor for sensing the presence of a pad in the staging area and generating a representative signal, and a pad retrieval system for retrieving the pad from the staging area, wherein the cushioning conversion machine produces a pad when the representative signal indicates that a pad is not present in the staging area and the retrieval system retrieves a pad when the representative signal indicates a pad is in the staging area.

Abstract: A cushioning conversion machine for converting stock material into a continuous strip of a cushioning product. The machine includes a stock-preparing assembly which prepares the stock material; a stock-shaping assembly which shapes the prepared stock material into a continuous strip having a pillow-like portion and at least one tab portion projecting therefrom; and a tab-connecting assembly which connects the tab portion of the continuous strip whereby the pillow-like portion will maintain its pillow-like geometry.

Abstract: A novel loading assembly for a cushioning conversion machine that eliminates the need to manually thread the stock material through the former of the machine. The loading assembly is disposed at one end of the machine and feeds the stock material through the former to the machine's feed assembly. Hence, a cushioning conversion machine and method for converting a stock material into a cushioning product comprises a former assembly which forms the stock material into a strip of cushioning; a downstream feed assembly located at a downstream end of the former assembly which feeds the strip of cushioning passing therethrough; a loader feed assembly located at an upstream end of the former assembly, the loader feed assembly which, when engaged, feeds the stock material through the former assembly to the feed assembly; and a loader operator assembly for selectively engaging and disengaging the loading assembly.

Abstract: This invention relates to a product packaging material and method, and in particular to a product packaging material (27) formed from a length of rolled corrugated paper (20) and a method of manufacture therefor. There is provided a packaging material comprising corrugated paper (20), the corrugated paper including non-sinusoidal corrugations (16, 18, 72). There is also provided a method of making a packaging material of multi-layer corrugated paper (27) including the steps of forming corrugated paper (20) having a sheet with sinusoidal corrugations (42), and compressing the sheet to destroy the sinusoidal form of at least some of the corrugations.

Abstract: A cushioning conversion system (10) including a stand (12), a cushioning conversion machine (14), and a machine mounting assembly (16) which mounts the machine to the stand in such a manner that the machine may be selectively rotated relative to the stand in a horizontal plane.

Abstract: A cushioning conversion machine and method for converting multiple layer of sheet-like stock material into a cushioning product, characterized by a first shaping device which shapes a first layer of the stock material into a casing with the lateral edge portions being brought into overlapping relationship one inside the other, a second shaping device which shapes at least one second layer of the stock material into a stuffing for the for the casing, a connecting assembly downstream of the first shaping device for connecting the overlapped lateral edge portions of the first layer separate from the stuffing, and an inner feed assembly downstream of the second shaping device for feeding the second layer into the interior of the casing. The machine further comprises an outer feed assembly for engaging and feeding a central portion of the first layer, the outer and connecting assemblies being cooperative to pull the first layer through the first shaping device.

Abstract: A method of producing a packing product includes the steps of feeding at least one sheet of material in a first direction; cutting the at least one sheet of material into a plurality of strips; the cutting being performed by rotating two sets of alternating, overlapping cutting discs; the feeding of the at least one sheet of material being between the two sets of cutting discs; advancing each of the strips by the rotating of at least an outer surface of a corresponding one of the cutting discs as the outer surface moves in the first direction; restricting each strip from continued advancing in the first direction; and sequentially folding each of the strip means by the restricting in opposition to the advancing. There is included apparatus and means for producing the packing product.

Abstract: A cushioning conversion machine for converting sheet-like stock material into a cushioning product. The machine comprises a frame; a forming assembly which forms the sheet-like stock material into a three-dimensional strip of dunnage; a stock supply assembly which supplies the sheet-like stock material to the forming assembly; and a feed assembly which feeds the stock material through the forming assembly. The feed assembly includes a pair of shafts transversely movable relative to each other, a pair of rotating members mounted on respective shafts through which the strip of dunnage passes, a biasing member which urges one shaft towards the other shaft and thus one rotating member towards the other rotating member, and an adjustment member which adjusts the tension between the rotating members.

Abstract: The invention relates to a composite cushioning system for protecting articles, packaged within a box, from damage while being transported in the box. The composite structure includes an expansion sheet of expanded slit sheet, in combination with a separator sheet. The expanded sheet has a slit pattern which produces open cells, preferably of a hexagonal configuration. The separator sheet precludes the nesting of legs and lands of the slit sheet with other slit sheet of the same slit pattern. A variety of combinations of separator sheets and expansion sheets can be used, such as a pair of expansion sheets with a separator sheet between the pair of expansion sheets, or two such pairs of expansion sheets, with or without a separator sheet between the pairs. The separator sheet can be unslit, or tear-perforated or slit to accommodate expansion. Where the separator sheet is slit, the slits preferably produce the same amount of expansion as produced in the expansion sheets.

Abstract: In combination, a cushioning conversion machine and a dispensing table, the cushioning conversion machine connected underneath the dispensing table by a guide system. The guide system includes at least one multiposition guide track connected to the dispensing table in cooperative relation with a follower connected to the cushioning conversion machine, whereby the cushioning conversion machine can be withdrawn out either the front, rear, or either side of the dispensing table.

Abstract: Loose fill packaging material consists of elements (21) having a central liner (15) and a corrugated medium (17) on both sides of the liner. The element is made from fibreboard material. A method is disclosed of making the element by securing together the liner of a folded sheet of single faced corrugated fibreboard or securing together the liners of two sheets.

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: The present invention relates of a method and apparatus for making an improved resilient packing material by forming, resiliently folding and crimping shredded strips of moistened paper material into an improved interlocking, bulk, packaging material. The method and apparatus includes a wetting or dampening system which can be selectively varied to regulate the moisture content of moistened paper material.

Abstract: A tubular dunnage element or paperboard or the like has a tucked or heart-shaped radial cross section, and a slanted axial cross section. The element may be compressed by opposed inward forces along any line through the center of the element. The element is suited for use as a loose fill packing material. Serrated edges cause the elements in a bed to catch on one another, resisting the tendency of a packed article to migrate through the bed to a wall of a container under the influence of vibration occurring during shipment.

Abstract: A cushioning conversion machine for converting stock material into a continuous strip of a cushioning product. The machine includes a stock-preparing assembly which prepares the stock material; a stock-shaping assembly which shapes the prepared stock material into a continuous strip having a pillow-like portion and at least one tab portion projecting therefrom; and a tab-connecting assembly which connects the tab portion of the continuous strip whereby the pillow-like portion will maintain its pillow-like geometry.

Abstract: A cushioning conversion machine (20) and a dispensing table (100), in combination, are provided. The dispensing table (100) includes a substantially horizontal work platform (102) which includes an opening (109). The cushioning conversion machine (20) is mounted to the table (100) in such a manner that the cushioning product is deposited on the work platform (102) during operation of the machine. In this manner, a worker may conveniently place the cut section in a shipping case, or box, to fill any voids and/or to cushion an item during the shipping process.

Abstract: A modular cushioning conversion machine for converting a sheet-like stock material into a cushioning dunnage product characterized by first and second modular units. The first unit includes a housing and a forming assembly within the housing which forms the sheet-like stock material into a three-dimensional strip. The second unit includes a housing and a feed mechanism within the housing which feeds the sheet-like stock material through the forming assembly. The housings of the first and second units respectively have an outlet opening and an inlet opening positionable with respect to one another to provide a pathway for the transfer of the strip from the first unit to the second unit.

Abstract: Packing material and method in which a sheet of paper stock is folded in opposite directions along alternate parallel lines to form a series of ridges and valleys, cuts are made in the stock at intervals spaced along the ridges, and sections of the stock adjacent to the cuts are folded in a reverse direction along the fold lines at the ridges to form downwardly extending pleats beneath the ridges. The material can be crumpled for use as a dunnage material or wrapped about an item to be protected. In one disclosed embodiment, the material can be compressed for shipping and storage and expanded for use. In another, which is particularly suitable for use as a protective wrap, the folded stock is affixed to a backing sheet.

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 method and apparatus characterized by slitting a sheet of material having a natural resilience into a plurality of strips to form a body of such strips and folding each of the strips into a zig-zag shape. The folding step/function is accomplished by advancing the plurality of strips against a restriction acting on the body of strips in such a manner that the natural resilience of the material produces substantially uniform adjacent opposite folds thereby causing each of the strips to assume a zig-zag shape.

Abstract: A loose fill packing element consisting of a concave body of molded non-woven paper fibers having a wall of varying thickness with ridges thereon and having a shape of two irregular bulbous end portions on the opposite sides of a smaller central waist portion.

Abstract: A cushioning conversion machine, which converts stock material into cut sections of dunnage, includes a cutting/aligning assembly. The cutting/aligning assembly comprises a moving blade unit which is mounted on the frame in such a manner that it travels between a rest position and a cutting position whereat it cuts a dunnage strip (which is emerging from a dunnage outlet opening) into a cut section. The cutting/aligning assembly also includes an automatic alignment device which automatically aligns the cut section with the dunnage outlet opening when the blade unit is moved from the cutting position to the rest position. The automatic alignment device is unattached to the moving blade member but travels therewith during jam-free operation of the cushioning conversion machine.

Abstract: The invention concerns a package padding and an apparatus for forming same. The package padding is continuous and web-like and formed of superimposed paper courses (1,2,3). On the substantial surface area of one paper course (2) has with a pair of shaping rolls (16,17) been embossed a cellular padding structure. The package padding comprises a punch joint region (5) formed with the aid of a pair of punch joint rolls (18,19), and an intact area (7) substantially free of punchings, the package padding being more bulky and fluffy in the region thereof than in the punch joint region (5). In the embossed paper course (2) have by means of the speed differential of the punching rolls (18,19) and the shaping rolls (16,17) been folded pleats (8) so that the package padding contains per unit length of the package padding a greater length of paper material of the second paper course (2) than of paper material of the first paper course (1).

Abstract: Disclosed is a flat type pulp-molded cushioning material on which a number of raised portions are provided to serve as shock absorbers and a plurality of notches are provided at predetermined positions to allow said flat cushioning material to be folded along said notches to form a box-like means with a desired configuration corresponding to the shape of an article to be packed therein. The erected portions of the flat material can be suitably limited in place by the side walls of an outer packing container, which together with the fitly contact of the cushioning material with the packed article provide enhanced effect of cushioning. Moreover, the flat cushioning material can be molded more easily and can be more conveniently stored and transported at lower cost.

Abstract: In combination, a dispensing table (10) and a cushioning conversion machine (12) which is slidably mounted to the table (10). The table (10) includes a substantially horizontal work platform (14) and the machine (12) is situated below the platform (14). The cushioning conversion machine (10) includes conversion assemblies (50, 52, 54, 56, 58) which convert stock material (S) into a cushioning product (P). The cushioning conversion machine (12) is slidable to an operating position whereat the cushioning product (P) is deposited on the work platform (14) during operation of the machine. Preferably, the machine (12) is also slidable to an upstream position whereat its upstream portion projects outwardly from the table (10) and loading and threading procedures can be easily performed.