Downsized cushioning dunnage conversion machine and packaging systems employing the same

A cushioning conversion machine for converting sheet-like stock material, such as paper in multi-ply form, into cut sections of relatively low density pad-like cushioning dunnage product, said machine comprising:

• a frame including a frame base plate having an upstream end and a downstream end, a first upstream frame end plate extending generally perpendicularly from said upstream end of said frame base plate and a second downstream frame end plate extending in substantially the same direction as said first frame end plate from said downstream end of said frame base plate;
• a forming assembly, mounted on said base frame plate intermediate said upstream end and said downstream end, which causes inward rolling of the lateral edges of such sheet-like material into a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portions separated by a thin central band is formed;
• a stock supply assembly, located upstream of said forming assembly and mounted on said first frame end plate, which supplies such stock material to said forming assembly;
• a pulling/connecting assembly, located downstream of said forming assembly and mounted on an upstream side of said second frame end plate, which pulls such stock material from said stock supply assembly and through said forming assembly to form such continuous unconnected strip and which connects such continuous unconnected strip along such central band whereby a coined strip of pad-like cushioning dunnage product is formed;
• and
• a cutting assembly, mounted on an opposite downstream side of said second frame end plate and thereby being located downstream of said pulling/connecting assembly, which cuts such coined strip into cut sections of a desired length;
• said cutting assembly including a stationary blade and a sliding blade which coact in a guillotine fashion to cut such coined strip into such cut sections;
• said second downstream frame end plate having an outlet opening dimensioned to allow such coined strip to pass from the upstream side of said second frame end plate to the downstream side of said second frame end plate;
• said outlet opening having a proximal side, a distal side and two lateral sides;
• said stationary blade being fixedly mounted on the downstream side of said second frame end plate and is aligned with said proximal side of said outlet opening;
• said sliding blade being slidably mounted on the downstream side of said second downstream end plate within cutter guide bars;
• and
• said cutter guide bars being positioned beyond and parallel to said lateral sides of said outlet opening and also extending beyond said distal side and said proximal side of said outlet opening whereby said sliding blade may travel from an open position completely clearing said blade outlet opening to a closed position beyond said stationary blade.

A cushioning dunnage conversion machine for converting sheet-like stock material, such as paper in multi-ply form, into cut sections of relatively low density pad-like cushioning dunnage product, said machine comprising:

• a frame having a downstream end and an upstream end;
• a forming assembly, mounted on said frame intermediate said upstream end and said downstream end, which causes inward rolling of the lateral edges of such sheet-like material in a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portion separated by a central band is formed;
• a stock supply assembly, mounted on said frame upstream of said forming assembly, which supplies such stock material to said forming assembly;
• a pulling/connecting assembly, mounted on said frame downstream of said forming assembly, which pulls such stock material rom said stock supply assembly through said forming assembly and for connecting such continuous unconnected strip along such central band whereby a coined strip of pad-like cushioning dunnage product is formed;
• a cutting assembly, mounted on said frame downstream of said pulling/connecting assembly, which cuts such coined strip into cut sections of a desired length;
• and
• a post-cutting constraining assembly, mounted on said frame downstream of said cutting assembly, which circumferentially constrains such cut sections.

A cushioning conversion machine for converting sheet-like stock material, such as paper in multi-ply form, into cut sections of relatively low density pad-like cushioning dunnage product, said machine comprising:

• a frame having a downstream end and an upstream end;
• a forming assembly, mounted on said frame intermediate said upstream end and said downstream end, which causes inward rolling of the lateral edges of such sheet-like material in a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portions separated by a central band is formed;
• a stock supply assembly, mounted on said frame upstream of said forming assembly, which supplies such stock material to said forming assembly;
• a pulling/connecting assembly, mounted on said frame downstream of said forming assembly, which pulls such stock material from said stock supply assembly through said forming assembly and which connects such continuous unconnected strip along such central band whereby a coined strip of pad-like cushioning dunnage product is formed;
• a cutting assembly, mounted on said frame downstream of said pulling/connecting assembly, which cuts such coined strip into cut sections of a desired length;
• and
• a post-cutting constraining assembly, mounted on said frame downstream of said cutting assembly, which circumferentially constrains such cut sections;
• wherein said post-cutting constraining assembly is funnel-shape and includes an upstream converging portion which tapers into a downstream rectangular tunnel portion.

A method of producing cut sections of relatively low density pad-like cushioning dunnage product, comprising the steps of:

• supplying a sheet-like multi-ply stock material;
• causing inward rolling of the lateral edges of the sheet-like stock material in a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portions separated by a central band is formed;
• connecting such unconnected strips along such central band whereby a coined strip of pad-like dunnage product is formed;
• cutting such coined strip into cut sections of a desired length;
• and
• circumferentially constraining such cut sections.

A method of producing a relatively low density pad-like cushioning product, comprising the steps of:

• supplying a sheet-like material;
• pulling such sheet-like material in a generally vertical direction;
• causing inward rolling of the lateral edges of the sheet-like stock material in a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portions separated by a central band is formed;
• pulling such continuous unconnected strip in a vertical direction;
• connecting such unconnected strip along such central band whereby a coined strip of pad-like cushion dunnage product is formed;
• cutting such coined strip into cut sections of a desired length;
• and
• circumferentially constraining such cut sections.

A cushioning dunnage conversion machine for converting sheet-like stock material, such as paper in multi-ply form, into cut sections of relatively low density pad-like cushioning dunnage product, said machine comprising:

• a frame including a frame base plate having an upstream end and a downstream end, a first upstream frame end plate extending generally perpendicular from said upstream end of said frame base plate and a second downstream frame end plate extending in substantially the same direction as said first frame end plate from said downstream end of said frame base plate;
• a forming assembly, mounted on said base frame plate intermediate said upstream end and said downstream end, which causes inward rolling of the lateral edges of such sheet-like material into a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portions separated by a thin central band is formed;
• a stock supply assembly, located upstream of said forming assembly and mounted on said first frame end plate, which supplies such stock material to said forming assembly;
• a pulling/connecting assembly, located downstream of said forming assembly and mounted on an upstream side of said second frame end plate, which pulls such stock material from said stock supply assembly and through said forming assembly to form such continuous unconnected strip and which connects such continuous unconnected strip along such central band whereby a coined strip of pad-like cushioning dunnage product is formed;
• a cutting assembly, mounted on an opposite downstream side of said second frame end plate and thereby being located downstream of said pulling/connecting assembly, which cuts such coined strip into cut sections of a desired length;
• said cutting assembly including a first blade and a second blade positioned to coact with said first blade to cut such coined strip into such cut sections;
• a motor, mounted on said frame base plate at substantially the same level as said forming assembly, for powering said cutting assembly;
• and
• a clutch assembly, mounted on said second down-stream frame end plate, for serving as an interface between said motor and said cutting assembly;
• wherein said cutting assembly further includes:
• a cutter linkage connected to at least one of said blades;
• a drive linkage pivotally connected to said cutter linkage;
• a motion disk having a tangential portion connected to said drive linkage;
• and
• a shaft connected to said motion disk and connected to said clutch assembly.

A cushioning dunnage conversion machine for converting sheet-like stock material, such as paper in multi-ply form, into a coined strip of relative low density pad-like cushioning dunnage product, said machine comprising:

• a frame having an upstream end and a downstream end;
• forming assembly, mounted on said frame intermediate said upstream end and said downstream end, which causes inward rolling of the lateral edges of such sheet-like material into a generally spiral-like form whereby a continuous unconnected strip having two lateral pillow-like portions separated by a thin central band is formed;
• said forming including a converging chute having a first portion and a second portion pivotally attached to said first portion whereby said chute may be opened for initial manual threading of the machine and closed for normal automatic operation;
• a stock supply assembly, mounted on said frame upstream of said forming assembly, which supplies such stock material to said forming assembly;
• and
• a pulling/connecting assembly, mounted on said frame downstream of said forming assembly, which pulls such stock material from said stock supply assembly and through said forming assembly and which connects such continuous unconnected strip along such central band whereby a coined strip of pad-like cushioning dunnage product is formed;
• and
• a cutting assembly which cuts such coined strip into cut sections of a desired length