Abstract:
A supply of single-ply, fan-folded sheet stock material (100) includes a holder that has inclined support surfaces (114, 116, 120, 122) and intersecting support walls (124, 126) that support the support surfaces in their inclined orientations. The holder has a W-shape cross-section, with inclined outer support surfaces (114, 116) and inclined inner support surfaces (120, 122) that may meet in the middle. The inner support surfaces generally are perpendicular to adjacent outer support surfaces to support a generally rectangular stack (102) and sub-stacks (110, 112) of single-ply, fan-folded sheet stock material. A method includes laying open a stack of single-ply fan-folded sheet stock material to form two sub-stacks of sheet stock material and operating a dunnage conversion machine to simultaneously draw sheet stock material from both sub-stacks of sheet stock material, thereby providing a two-ply sheet stock material for conversion into a dunnage product.
Abstract:
A dunnage conversion machine for converting an expandable pre-slit sheet stock material into a relatively less dense dunnage product includes an improved expansion assembly that provides means for adjusting the spacing between axes of rotation of components through which the sheet stock material is drawn. The adjustability enables pre-slit sheet stock materials of differing thicknesses and/or having differing slit patterns to be fed through the expansion assembly with no or minimal compression of an expanded dunnage product, jamming in the conversion machine, bunching, and/or tearing of the pre-slit sheet stock material or expanded dunnage product resulting from expansion of the pre-slit sheet stock material.
Abstract:
A dunnage conversion machine includes a bunching assembly that randomly crumples at least two plies of sheet stock material into modified plies having a relatively thicker three-dimensional shape, and a feeding assembly that advances and connects together longitudinally-extending portions of the modified plies to form a dunnage strip. A diverter minimizes overlap of and encourages separation of lateral edges of the modified plies from one another, and a severing assembly severs distinct dunnage products from the strip. An exemplary resultant dunnage product includes two or more plies of crumpled sheet material interconnected along a longitudinally-extending portion having interconnected overlapped portions of each of the plies and a longitudinally-extending line of connection. Each ply may extend laterally outwardly along randomly crumpled edge portions having a crumpled lateral width greater than a lateral width of the longitudinally-extending portion, the edge portions extending from the line of connection to opposed, laterally-extending free edges.
Abstract:
A method for making an insulating dunnage product includes the steps of (a) permanently deforming at least one non-planar interior layer that includes a paper sheet to form a plurality of air pockets; (b) surrounding the at least one interior layer on all four sides and over the top and bottom sides of the at least one interior layer with at least one outer layer of sheet material; and (c) peripherally sealing the at least one outer layer to capture the at least one interior layer therein such that the interior layer has major portions that are free to shift relative to adjacent portions of the at least one outer layer.
Abstract:
A method of loading a stack of sheet stock material for use by a dunnage conversion machine, includes the following steps: (i) providing first and second stacks, the second stack being protected by a carrier having a central portion and longitudinally-spaced extensions that bound a central portion, the extensions and the central portion being joined along a weakened area defining a tear line, the central portion and the longitudinally-spaced extensions forming a planar bottom panel and a planar side panel, each panel extending substantially the length of the stack, and at a right angle to each other about a fold line over a bottom and an adjacent side of the stack, and one or more bale ties longitudinally inwardly of the tear lines holding the carrier to the stack; (ii) removing the extensions from the carrier; (iii) setting the second stack on top of the first stack; and (iv) removing the bale ties and the carrier, whereby an adhesive bonds the top page of the first stack to the bottom page of the second stack.