Method and apparatus for producing individual rolls of packing material

An apparatus for forming a cushioning material for use as a packaging material comprising:

• a source of flexible material in its unexpanded form, said material having:
• a plurality of spaced parallel rows of individual slits extending transversely from one end ox the sheet material to the opposing end of said sheet material, each of said rows having interval spaces between consecutive slits;
• said slits in each row being positioned adjacent the interval space between consecutive slits in the adjacent parallel row of slits;
• a first pair of drive rolls,
• a second pair of expander rolls,
• said flexible material extending from said source to said pair of driver rolls, said material passing between said drive rolls to said expander rolls,
• at least one of said expander rolls having slit material gripping means on its surface, whereby rotation of said driver rolls draws material from its source and rotation of said expander rolls at a rotational speed greater than the rotational speed of said driver rolls expands the material, said gripping means on said expander rolls engaging said material without crushing the expanded material,
• said sheet being expanded by extending the opposing ends of each sheet between said drive rolls and said expander rolls, parallel to the rows of slits whereby the slits form an array of openings, each opening being generally similar in shape and size,
• said sheet in substantially expanded form having a sufficient load bearing capacity and sufficient elastic potential energy to protect an article in transit against impact damage, by cushioning the article,
• said slit material gripping means being a plurality of moderately firm bristles uniformly distributed along the surface of at least one expander roll.