Cushioning conversion machine and method with enhanced stock separation and forming

An internal forming device for a cushioning conversion machine, intended to be positioned at least partially within an external forming device of the machine, comprising a central guide portion having a bottom guide surface extending substantially continuously from an upstream end to a downstream end of the internal forming device for guiding a central region of the sheet stock material as its lateral regions are inwardly turned, and a cascade portion of the internal forming device including multiple stages disposed above the bottom guide surface of the central guide portion and defining therebetween relatively relieved areas in lateral regions of the internal forming device that facilitate the formation of creases in the lateral regions of the sheet stock material, wherein each stage has a top guide surface and lateral guide surfaces depending from the top guide surface, the lateral guide surfaces forming lateral edges inclined relative to the top guide surface.

A cushioning conversion machine for converting sheet stock material into a relatively lower density cushioning product as the sheet stock material moves through the machine from an upstream end toward a downstream end, comprising a forming assembly including an internal forming device and an external forming device, the internal forming device having at least one top portion with a pair of generally longitudinally converging and coplanar lateral top edges, and at least one lateral side edge depending from each top edge and longitudinally inclined relative to the plane of the top edge the internal forming device further including a base plate forming a substantially continuous surface extending at least within the external forming device to cooperatively guide central regions of the stock material therebetween;

• the external forming device having converging sidewalls cooperating with the internal forming device to inwardly turn lateral regions of the stock material.