System and method for crumpling paper substrates

An apparatus for crumpling a length of sheeting material for making a cushioning product, comprising:

• 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 magnet having a magnetic force for holding said second roller adjacent said first roller, the magnet and second roller being configured for allowing the second roller to automatically move away from said first roller to disengage the sheeting material from the first roller when the sheeting material overloads between the first roller and second roller and creates a force that exceeds a magnetic force of the magnet.

An apparatus for crumpling sheeting material for making a cushioning product, comprising:

• a holder for a roll of sheeting material, said holder comprising a brake arm having a tapered cap for disposing in an opening of said roll of sheeting material such that the cap brakes the spin of the roll as sheeting material is removed from said roll;
• a guide comprising a plurality of longitudinally curved tines spaced apart from each other laterally to define a plurality of empty spaces between the plurality of longitudinally curved tines for creating troughs in the sheeting material, for guiding the sheeting material and disposing a wave pattern in said sheeting material when viewed as a cross-section of said sheeting material;
• a crumpling zone disposed downstream said guide, wherein the crumpling zone crumples the sheeting material fed thereinto by the guide, said crumpling zone comprising a drive roller and a pinch roller, the drive roller and pinch roller pulling the sheeting material from the holder and applying tension to the sheeting material such that the sheeting material pulled over the tines is biased into the empty spaces to form a wave pattern due to the longitudinal curvature of the tines, and said sheeting material disposed between the drive roller and said pinch roller, said drive roller and said pinch roller crumpling said sheeting material traveling therebetween;
• and
• a cutting mechanism for cutting said sheeting material after said sheeting material has been crumpled.

An apparatus for crumpling a length of sheeting material for making a cushioning product comprising:

• a support member configured for supporting a supply of sheeting material;
• a feeder configured for feeding the sheeting material from the supply mechanism to a crumpling mechanism, wherein said feeder comprises a guide comprising a plurality of longitudinally curved members spaced apart from each other laterally about an imaginary surface that is convex both longitudinally and laterally, defining a plurality of empty spaces therebetween such that the sheeting material under tension is pulled over the plurality of longitudinally curved members and is biased into the empty spaces to form a wave pattern due to the longitudinal curvature of the members;
• and
• a drive mechanism configured for applying sufficient tension in the sheeting material over the feeder for forming the wave pattern.