HK40019763B - Dunnage supply intake - Google Patents

Description

Gasket supply inlet

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Patent Application No. 15/593,255, filed May 11, 2017, entitled “DUNNAGESUPPLY INTAKE” (pending), the entire contents of which are incorporated herein by reference.

Technical Field

The present invention is in the field of protective packaging systems and materials, and in particular for the conversion of raw materials used in protective packaging systems.

Background Art

In the context of paper-based protective packaging, sheets of paper are crumpled to produce cushioning. Most commonly, this type of cushioning is formed by feeding a generally continuous strip of paper into a cushioning conversion machine, which converts a compact stock supply (e.g., a roll of paper or a stack of fan-folded paper) into a less dense cushioning material. The stock supply (e.g., in the case of fan-folded paper) is pulled into the conversion machine from a stack that is either continuously formed or formed into discrete sections connected together. The continuous strip of crumpled sheet material can be cut into the desired length to effectively fill the void space within the container holding the product. The cushioning material can be produced according to the needs of the packaging machine.

Various types of raw materials are used to form gasket materials. One method of converting raw materials into a less dense gasket is by constricting the path of the raw material through a funnel or similar constriction device. Some conventional devices can cause degradation of the raw material, such as tearing, as the path compresses the raw material along the constricted portion of the path.

Summary of the Invention

Disclosed herein is a gasket conversion station that pulls a sheet of raw material from a supply station in a longitudinal direction and converts the raw material into a low-density gasket. The gasket conversion station may include an inlet member. The gasket conversion station also includes a stock forming member located upstream of the inlet member and located on an upstream portion of the conversion station to bend the raw material pulled from the supply station around a transverse axis extending approximately transverse to the longitudinal direction. The stock forming member may include a support structure that extends in a direction approximately the same as the transverse axis and bends the raw material around the transverse axis. The stock forming member may include a central protrusion that protrudes deeper into the curved portion of the raw material than the support structure. When the raw material moves longitudinally across the support structure and the central protrusion, the central protrusion can bend the raw material around both the transverse axis and the longitudinal axis extending approximately centrally into the raw material in the longitudinal direction.

According to embodiments discussed herein, a central protrusion can extend radially from the support structure. The liner conversion station can include a drive mechanism operable to draw the stock material into the inlet member. The inlet can include a structural member defining an opening disposed between the shaping member and the drive mechanism. The opening can constrict the stock material as it is drawn longitudinally into and through the liner inlet member. The shaping member can manipulate the path of the stock material in a manner that causes it to initially bend or curl before being drawn into the inlet member. The support structure can extend over a span less than the full width of the stock material. Alternatively, the support structure can extend over a span exceeding the full width of the stock material. The support structure can be a laterally extending cylindrical rod. The rod can include a transverse free end that allows a sufficiently wide stock material to wrap around the free end. The central protrusion can be a semicircular protrusion having an axis perpendicular to the transversely extending axis of the support structure. The central protrusion can extend away from the support member a distance between approximately 1/10 and 1/2 the length of the support structure. The central protrusion can extend rearwardly from a horizontal plane passing through the central axis of the support structure by an angle between approximately 15° and 75°. The shaping member may be connected to the liner inlet member by a connecting member extending therefrom. The shaping member may be positioned to change the direction of the stock material as it is pulled from the supply station and through the inlet. The shaping member may be 2 to 8 times wider than the opening.

The liner system may include the liner conversion station described above and a feed station configured to accommodate stock material. The feed station may be configured to accommodate stock material that is wider than the width of the forming member.

Disclosed herein is a liner conversion machine having a liner conversion station. The liner conversion station may include an external structure defining an opening that constricts the stock material as it is drawn into and through a liner inlet member. The liner conversion station may include a transverse barrier member extending from the external structure in a direction corresponding to a transverse width of the stock material drawn into and through the liner inlet, such that the transverse barrier member restricts the stock material from wrapping around the external structure and does not significantly restrict the stock material in an upstream direction. The liner conversion station may include a drive mechanism located downstream of the conversion station. The drive mechanism may receive and draw the stock material through the liner inlet member.

According to embodiments described herein, the transverse barrier member may include ears that protrude laterally from the gasket inlet and have a height less than the gasket inlet. At least one ear may form an attachment to the bracket. The transfer station may also include a shaping member located upstream of the inlet. The shaping member may be configured to manipulate the stock material along its path in a manner that causes it to initially bend or curl before being drawn into the inlet.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate one or more embodiments according to the present disclosure by way of example only and not limitation.In the accompanying drawings, like reference numerals refer to the same or similar elements.

FIG1A is a perspective view of an embodiment of a pad conversion system;

FIG1B is a rear view of the embodiment of FIG1A of the pad conversion system;

FIG1C is a side view of the embodiment of FIG1A of the pad conversion system;

FIG2A is a perspective view of another embodiment of a pad conversion system;

FIG2B is a rear view of the embodiment of FIG2A of the pad conversion system;

FIG2C is a side view of the embodiment of FIG2A of the pad conversion system;

FIG3 is a perspective view of a portion of the embodiment of the liner conversion machine of FIG1A-2C;

FIG4A is a right side view of the embodiment of the forming member of FIG3;

FIG4B is a rear view of the embodiment of the shaping member of FIG3;

FIG4C is a left side view of the embodiment of the forming member of FIG3;

FIG4D is a top view of the embodiment of the forming member of FIG3;

FIG5 is a rear view of the embodiment of the inlet of FIG3; and

6 is a rear isometric view of a liner system with curved supports for daisy-chained stock.

DETAILED DESCRIPTION

Disclosed are systems and apparatus for converting stock into cushioning. The present disclosure is generally applicable to systems and apparatus for processing a supply material, such as stock. The stock is processed through a longitudinal crimper, which forms longitudinal pleats in the stock to form the cushion, or through a cross-crimper, which forms transverse pleats in the stock. The stock can be stored in rolls (whether drawn from the inside or outside of the roll), bales, fan-folded feeds, or any other suitable form. The stock can be continuous or perforated. A conversion device is operable to drive the stock in a first direction, which can be an anti-runout direction. The conversion device feeds the stock from a storage reservoir via rollers in the anti-runout direction. The stock can be any suitable type of protective packaging material, including, for example, other cushioning and void-filling materials, inflatable packaging pads, and the like. Some embodiments utilize a supply of other paper or fiber-based materials in sheet form, while some embodiments utilize a supply of wound fiber materials, such as rope or string, and thermoplastic materials, such as webs of plastic materials that can be used to form cushioning pads. Examples of paper used include fan-folded stock sheets having a width of 30 inches across and/or a width of 15 inches across. Preferably, these sheets are fan-folded into a single layer. In other embodiments, multiple layers of sheet material can be fan-folded together such that the liner is made of overlapping sheets that are crumpled together.

The conversion device is used in conjunction with a cutting mechanism that is operable to sever the cushioning material. More particularly, the disclosed conversion device includes a mechanism for cutting or assisting in cutting the cushioning material to a desired length. In some embodiments, the cutting mechanism is used without user interaction or with limited user interaction. For example, the cutting mechanism pierces, cuts, or severs the cushioning material without the user touching the cushioning material or with the user only lightly contacting the cushioning material. Specifically, a biasing member is used to bias the cushioning material onto or around the cutting member to enhance the system's ability to sever the cushioning material. The biased position of the cushion is used in conjunction with or separately from other cutting features, such as reversing the direction of travel of the cushioning material.

With reference to Figures 1A, 1B, 1C and 2A, 2B, and 2C, a cushion conversion system 10 is disclosed. The cushion conversion system 10 may include a supply of stock material 19 and one or more cushioning devices 50. The cushioning device 50 may include one or more of a supply station 13 and a cushion conversion machine 100. The cushion conversion machine 100 may include one or more of a conversion station 60, a drive mechanism 250, and a support member 12. Generally, the cushion conversion system is operable to process the stock material 19. According to various embodiments, the conversion station 60 includes an inlet 70 that receives the stock material 19 from the supply station 13. The drive mechanism 250 is capable of drawing or assisting in drawing the stock material 19 into the inlet 70. In some embodiments, the stock material 19 engages a forming member 200 prior to the inlet 70. The forming member 200 may include a central protrusion 210 adapted to initiate a bend in the stock material 19 prior to entering the inlet 70. The drive mechanism 250, in conjunction with the cutting edge 112, assists a user in cutting or severing the cushion material 21 at a desired location. The gasket material 21 is converted from stock material 19 , which itself is delivered from a bulk supply 61 and conveyed to a conversion station for conversion into gasket material 21 , and then passes through a drive mechanism 250 and cutting edge 112 .

According to various examples, as shown in Figures 1A and 1B, the raw material 19 is dispensed from a bulk supply source shown as a plurality of raw material units 300a-e, but may also be a single raw material unit 300. The raw material 19 can be stored as stacks of fan-folded material. However, as described above, any other suitable type of supply or raw material can be used. The raw material 19 can be housed in a supply station 13. In one example, the supply station 13 is a cart 34 that can be moved relative to the liner conversion system 10 (e.g., via one or more wheels 36). The cart 34 includes side walls 140a, 140b. For example, the side walls 140a, 140b can extend from the base members 37 and 34, respectively. The side walls 140a, 140b can define a box 130 suitable for accommodating a plurality of raw material units 300, from which the raw material 19 can be pulled. In other examples, the supply station 13 is immovable relative to the liner conversion system 10. For example, the supply station 13 may be a single box, basket, or other container mounted to or near the liner conversion system 10 .

Stock material 19 is fed from the supply side 61 through an inlet 70. The stock material 19 is initially converted from a dense stock material 19 to a less dense cushioning material 21 through the inlet 70 and then drawn through the drive mechanism 250 and dispensed in the anti-tracking direction A at the discharge side 62 of the inlet 70. The material can be further converted by the drive mechanism 250 by allowing rollers or similar internal components to wrinkle, fold, flatten, or perform other similar methods that further tighten the folds, wrinkles, creases, or other three-dimensional structures created through the inlet 70 into a more permanent shape to form a low-density configuration of the cushioning material. The stock material 19 can include continuous (e.g., a continuously connected stock material pile, roll, or sheet), semi-continuous (e.g., separate stock material piles or rolls), or discontinuous (e.g., individual discrete or short lengths of stock material) stock material 19 to allow for continuous, semi-continuous, or discontinuous feeding into the cushioning conversion system 10. Multiple lengths can be connected together in a daisy-chain manner. Furthermore, it will be appreciated that various configurations of inlet 70 on a longitudinal crimping machine may be used, such as those forming part of the conversion stations disclosed in U.S. Patent Publication No. 2013/0092716, U.S. Patent Publication No. 2012/0165172, U.S. Patent Publication No. 2011/0052875, and U.S. Patent No. 8,016,735. Examples of cross-crumping machines include U.S. Patent No. 8,900,111.

In one configuration, the liner conversion system 10 can include a support portion 12 for a support station. In one example, the support portion 12 includes an entry guide 70 for guiding the sheet material into the liner conversion system 10. The support portion 12 and the entry guide 70 are shown, wherein the entry guide 70 extends from a post. In other embodiments, the entry guides can be combined into a single rolled or curved elongated element that forms a portion of a support rod or post. The elongated element extends from a base that is configured to provide lateral stability to the conversion station. In one configuration, the entry guide 70 is a tubular member that also serves as a support member for supporting the stock material 19, crimping the stock material 19, and guiding the stock material 19 toward the drive mechanism 250. Other entry guide designs (e.g., bobbins) can also be used.

According to various embodiments, the travel mechanism is an electromechanical drive device such as an electric motor 11 or a similar power device. The motor 11 is connected to a power source such as an outlet via a power cord and is arranged and configured to drive the pad conversion system 10. The motor 11 is an electric motor, wherein the operation is controlled by a user of the system, such as by a foot pedal, switch, button, etc. In various embodiments, the motor 11 is part of a drive portion, and the drive portion includes a transmission device for transmitting power from the motor 11. Alternatively, a direct drive can be used. The motor 11 is arranged in a housing and fixed to a first side of a center housing, and the transmission device is housed in the center housing and is operably connected to the drive shaft and drive portion of the motor 11, thereby transmitting the power of the motor 11. Other suitable power devices can be used.

Motor 11 is mechanically connected to roller 17 shown in FIG3 , either directly or via a transmission, which causes roller 17 to rotate with motor 11. During operation, motor 11 drives roller 17 in a counter-tracking or reverse direction (i.e., a direction opposite to the counter-tracking direction), which causes roller 17 to dispense cushioning material 21 by driving the cushioning material in the counter-tracking direction as shown by arrow "A" in FIG1C and FIG2A-2C or retrieving the cushioning material 21 into the converter in the direction opposite to A. Stock material 19 is fed from supply side 61 of inlet 70 and passed through roller 17 to form cushioning material 21, which is driven in the counter-tracking direction "A" when motor 11 is operated. Although described herein as a roller, this element of the drive mechanism may also be a wheel, a conveyor, a belt, or any other suitable device operable to advance the stock material or cushioning material through the system.

According to various embodiments, the liner conversion system 10 includes a clamping portion that is operable to press on the material as the material passes through the drive mechanism 250. As an example, the clamping portion includes a clamping member such as a wheel, roller, slide, belt, multiple elements or other similar members. In one example, the clamping portion includes a pinch wheel 14. The pinch wheel 14 is supported by bearings or other low-friction devices on an axis arranged along the axis of the pinch wheel 14. In some embodiments, the pinch wheel can be powered and driven. The pinch wheel 14 is positioned adjacent to the roller so that the material passes between the pinch wheel 14 and the roller 17. In various examples, the pinch wheel 14 has a circumferential pressing surface that is arranged to be adjacent to or tangentially contacted with the surface of the roller 17. The pinch wheel 14 can have any suitable size, shape or configuration. Examples of the size, shape and configuration of the pinch wheel can include those described for the pinch wheel in U.S. Patent Publication No. 2013/0092716. In the example shown, the nip wheels 14 are engaged in a position biased against the rollers 17 for engaging and crushing stock 19 passing between the nip wheels 14 and the rollers 17 to convert the stock 19 into a cushioning material 21. The rollers 17 or nip wheels 14 are connected to the motor 11 via a transmission (e.g., a belt drive, etc.). The motor 11 rotates the rollers or nip wheels.

According to various embodiments, the drive mechanism 250 can include a guide member operable to guide the material as it passes through the clamping portion. In one example, the guide member can be a flange 33 mounted to the drum 17. The diameter of the flange 33 can be larger than the diameter of the drum 17 so that the material is retained on the drum 17 as it passes through the clamping portion.

The drive mechanism 250 controls the incoming liner material 19 in any suitable manner to advance it from the conversion device to the cutting member. For example, the nip wheel 14 is configured to control the incoming material. As the high-speed incoming material diverges in the longitudinal direction, a portion of the material contacts the exposed surface of the nip wheel, pulling the diverging portion down onto the rollers and helping to crush and crumple the resulting bunched material. The liner can be formed using any suitable technique, including those described herein or known techniques, such as those disclosed in U.S. Patent Publication No. 2013/0092716.

According to various embodiments, the conversion device 10 is operable to change the direction of the stock material 19 as it moves within the conversion device 10. For example, the stock material 19 is moved in a forward direction (i.e., from the inlet side to the anti-tracking side) or a reverse direction (i.e., from the anti-tracking side to the supply side 61 or a direction opposite to the anti-tracking direction) by the combination of the motor 11 and the roller 17. This ability to change direction allows the drive mechanism 250 to more easily cut the cushioning material by pulling the cushioning material 19 directly against the cutting edge 112. As the stock material 19 is fed through the system and the cushioning material 21, it passes over the cutting edge 112 or approaches the cutting edge without being cut.

Preferably, the cutting edge 112 is curved or oriented downwardly to provide guidance that deflects the material in the outfeed portion of the path as the material exits the system near and possibly around the cutting edge 112. The cutting member 110 can be curved at an angle similar to the curvature of the drum 17, but other angles of curvature can be used. It should be noted that the cutting member 110 is not limited to using a sharp blade to cut the material, but rather it can include members that facilitate other methods of breaking, tearing, slicing, or severing the liner material 21. The cutting member 110 can also be configured to completely or partially sever the liner material 21.

In various embodiments, the lateral width of the cutting edge 112 is preferably at most approximately the width of the roller 17. In other embodiments, the width of the cutting edge 112 can be less than the width of the roller 17 or greater than the width of the roller 17. In one embodiment, the cutting edge 112 is fixed; however, it should be understood that in other embodiments, the cutting edge 112 can be movable or pivotable. The cutting edge 112 is oriented away from the drive portion. The cutting edge 112 is preferably configured to be sufficient to engage the cushioning material 21 when the cushioning material 21 is pulled in the opposite direction. The cutting edge 112 can include a sharp or blunt edge with a toothed or smooth structure, and in other embodiments, the cutting edge 112 can have a serrated edge with many teeth, an edge with shallow teeth, or other effective structure. The multiple teeth are defined by points separated by grooves between the teeth.

Typically, the gasket material 21 follows a material path A as shown in FIG1C . As described above, the material path A defines the direction in which the material 19 moves through the system. The material path A has various sections, such as an infeed section from the supply side 61 and a severable section 24. The gasket material 21 on the discharge side 62 generally follows the path A until it reaches the cutting edge 112. The cutting edge 112 provides a cutting location for severing the gasket material 21. The material path may bend at the cutting edge 112.

As mentioned above, any suitable raw material can be used. For example, the basis weight of the raw material can be about at least 20 lbs, at most about 100 lbs. The raw material 19 comprises a paper raw material stored in a high-density configuration with a first longitudinal end and a second longitudinal end, which is subsequently converted into a low-density configuration. The raw material 19 is a sheet material strip that is stored in a fan-shaped folded structure (as shown in Figure 1A) or stored in a coreless roll. The raw material is formed or stored as a single layer or multilayer material. When using a multilayer material, one layer can include multiple sublayers. It should also be understood that other types of materials can be used, such as pulp-based virgin paper and recycled paper, newsprint, cellulose and starch compositions, and polyester or synthetic materials with suitable thickness, weight and size.

In various embodiments, the stock unit may include an attachment mechanism that can connect multiple stock units (e.g., to create a continuous stock feed from multiple discrete stock units). Preferably, the adhesive portion facilitates daisy-chaining the rolls together to form a continuous stream of sheet material that can be fed into the conversion station 60.

Generally, the feedstock 19 can be provided as any suitable number of discrete feedstock units. In some embodiments, two or more feedstock units can be connected together to provide a continuous feed of material that is fed sequentially or simultaneously (i.e., in series or in parallel) through the connected units to the liner converting machine. Moreover, as described above, the feedstock units can have any number of suitable sizes and configurations and can include any number of suitable sheet materials. Generally, the term "sheet material" refers to a material that is generally sheet-like and two-dimensional (e.g., wherein two dimensions of the material are significantly greater than a third dimension, such that the third dimension is negligible or extremely small compared to the other two dimensions). Moreover, the sheet material is generally flexible and foldable, such as the exemplary materials described herein.

In some embodiments, the raw material unit may have a fan-shaped folding structure. For example, a foldable material (e.g., paper) may be folded repeatedly to form a stack or a three-dimensional body. Compared to a "two-dimensional" material, the term "three-dimensional body" has three dimensions, all of which are non-negligible. In one embodiment, a continuous sheet (e.g., a sheet of paper, plastic, or foil) may be folded at a plurality of fold lines that extend transversely to the longitudinal direction of the continuous sheet or transversely to the feed direction of the sheet. For example, folding a continuous sheet having a substantially uniform width along a transverse fold line (e.g., a fold line oriented perpendicularly to the longitudinal direction) may form or define sheet segments having substantially the same width. In an embodiment, a continuous sheet may be folded sequentially in opposite or alternating directions to produce an accordion-shaped continuous sheet. For example, folding may form or define a plurality of segments along a continuous sheet that may be substantially rectangular.

For example, sequentially folding a continuous sheet can produce an accordion-shaped continuous sheet having sheet segments of approximately the same size and/or shape as one another. In some embodiments, a plurality of adjacent segments defined by fold lines can be generally rectangular and can have the same first dimension (e.g., corresponding to the width of the continuous sheet) and the same second dimension generally along the longitudinal direction of the continuous sheet. For example, when adjacent segments are in contact with one another, the continuous sheet can be configured into a three-dimensional body or stack (e.g., the accordion shape formed by the folding can be compressed so that the continuous sheet forms a three-dimensional body or stack).

It will be appreciated that the fold lines may have any suitable orientation relative to one another and to the longitudinal and transverse directions of the continuous sheet. Furthermore, a feedstock unit may have transverse folds that are parallel to one another (e.g., compressing the segments formed by the fold lines together may form a three-dimensional body in the shape of a rectangular prism) and may also have one or more folds that are non-parallel relative to the transverse folds.

The continuous sheet is folded at the transverse fold line to form or define a generally rectangular sheet segment. The rectangular sheet segments can be stacked together (e.g., by folding the continuous sheet in alternating directions) to form a three-dimensional body having longitudinal, transverse, and vertical dimensions. As described above, the raw material from the raw material unit can be fed through the inlet 70 (Figures 1A, 1B, 2A, 2B, and 3). In some embodiments, the transverse direction of the continuous sheet (e.g., the direction corresponding to the transverse dimension 302 (see, for example, Figure 6)) is greater than one or more dimensions of the inlet 70. For example, the transverse dimension of the continuous sheet can be greater than the diameter of the generally circular inlet. For example, reducing the width of the continuous sheet at its starting point can facilitate its entry into the inlet. In some embodiments, reducing the width of the leading portion of the continuous sheet can facilitate smoother entry and/or transition or entry of the daisy-chained continuous sheet, and/or can reduce or eliminate the possibility of the continuous sheet getting stuck or tearing. In addition, reducing the width of the continuous sheet at its starting point can facilitate connecting two or more raw material units together or connecting them in a daisy-chain manner. For example, connecting or daisy-chaining materials having tapered sections may require smaller connectors or splicing elements than for connecting comparable full-width sheets. Furthermore, tapered sections may be easier to manually align and/or connect together than full-width sheet sections.

As described above, the liner apparatus 50 may include one or more of the feed station 13 and the liner conversion machine 100 (as shown in Figures 1A-1C and 2A-2C). According to various embodiments, the feed station 13 is any structure suitable for supporting the stock material 19 and allowing the material to be introduced into the inlet 70. The liner conversion machine 100 may include one or more of the conversion station 60 and the support 12.

According to various embodiments, the conversion station 60 draws the stock liner from the supply station 13 and begins deforming the stock liner into a denser configuration. The crumpled material entering the conversion station is pulled by the drive mechanism 250 and into the drive mechanism 250, where rollers 17 further compress the crumpled material. This allows the crumpled material to be set by forming pleats along the crumpled areas so that the material maintains its crumpled form. According to various embodiments, the conversion station 60 includes a liner inlet 70. The liner inlet 70 receives the liner along path A (see Figures 1A-1C and 2A-2C).

As shown in Figures 3 and 5, the gasket inlet member 70 includes an inlet 71 that contracts the raw material as it is drawn into and through the gasket inlet member. The inlet 71 is defined by an external support member 72 that forms an outer barrier suitable for engaging and compressing the raw material 19 inwardly into a denser configuration. Preferably, the external support member 72 includes a lateral portion that can engage and compress the raw material 19 inwardly. In such an example, the external support member 72 is located at least on the lateral side of the path of the raw material through the conversion station 60. In various examples, the external support member 72 forms an outer periphery of the opening that defines the inlet 71. In some embodiments, the external support member 72 is not completely closed (i.e., forming a U-shape or similar design). In some embodiments, the external support member 72 forms the entire periphery but is not connected (i.e., forming a spiral or similar design). In some embodiments, the external support member 72 forms a completely closed and connected outer periphery. In one example, the external support member 72 is a continuous ring. Although shown as a circle, other shapes and designs are also suitable for contracting the raw material into the gasket material.

According to various embodiments, the gasket inlet member 70 may further include one or more support members (e.g., 74, 75) that form a barrier on one or more sides of the gasket inlet member 70. The support members (e.g., 74, 75) are positioned on the sides of the inlet member 70 based on the direction in which the feedstock is received into the inlet member 70. For example, when the feedstock is received into the inlet member 70, the support members (e.g., 74, 75) are positioned on the exterior of the inlet member 70, aligned with the lateral direction of the feedstock. In this manner, when the material 19 is drawn into the inlet 71, the lateral support members (e.g., 74, 75) limit the tendency of the feedstock to wrap around the support members 72 of the inlet member 70. In one example, the inlet member 70 includes support members 74, 75 that extend outward from the support members 72 on lateral sides of the support members 72a, 72b. In one example, the support members 74, 75 form ears that extend from the sides of the support members 72. In this manner, the ears limit the ability of the stock 19 to wrap around the exterior of the support 72, and thus the ears limit the likelihood of the stock 19 tearing as it is pulled through the inlet 71. The ears also project laterally from the support 72, with little structure extending upstream of the support 72. This allows for support in the lateral direction (i.e., anti-wrapping) without significantly restricting the stock 19 laterally in a direction upstream of the support 72.

According to one embodiment, inlet 70 includes a support member 72 formed as a doughnut. The interior of the support member is an aperture with a rounded edge 73 defining inlet 71. The rounded edge 73 allows for a smooth transition of the feedstock 19 through inlet 71, thereby limiting tearing. Transverse supports 74 and 75 may extend as ears from lateral sides 72a and 72b of support member 72. As used herein, ears are transverse supports 74 and 75 that protrude from support member 72 and have a height EH that is less than the height of support member 72. Height EH refers to the height of supports 74 and 75 at the sides of support member 72. In various embodiments, height EH is greater than width IW of inlet 71 but less than the overall height SW of support member 72. According to various embodiments, transverse supports 74 and 75 may have a width EW that extends from the outside of support member 72. Width EW represents the increase in the size of the barrier formed at the lateral ends of the inlet due to transverse supports 74 and 75. For example, the lateral sides of the inlet provide a larger barrier than the top or bottom of the inlet. In an alternative example, if the orientation of the feedstock varies so that the feedstock enters the inlet with its lateral width fluctuating up and down relative to the inlet, supports 74 and 75 will be located on top of or at the bottom of support 72. Width EW can be 1/2 to 1 1/2 times the width of support 72. In this manner, the barrier formed by supports 74 or 75 is 1 1/2 to 2 1/2 times larger than the barrier formed by support 72 alone.

According to various embodiments, a liner inlet 70 can be supported by the bracket 12. The inlet 70 can be mounted directly to the bracket 12, the drive mechanism 250, or an intermediate member. In one example, a support 75 includes an attachment bracket 76 mounted to the bracket 12. By mounting the inlet 70 to the bracket directly or via the support 75, the inlet 70 is more securely positioned and thus better able to handle forces caused by wrinkling of the stock at the inlet 71.

According to various embodiments, the conversion station 60 includes a liner forming member 200. The forming member 200 receives the liner material along a path A (see Figures 1A-1C and 2A-2C) and manipulates the path of the material to initially bend or curl it before it is drawn into the inlet. The material flows longitudinally upward and around one or more portions of the forming member 200. The forming member 200 is located upstream of the inlet 70. For example, the forming member 200 can be located between the inlet 70 and the feed station 13 so that as the material 19 flows longitudinally downstream from the feed station, it slides around the forming member 200, allowing the forming member 200 to manipulate the shape of the material 19 before it enters the inlet 71 of the inlet 70. As the material is drawn from the feed station 13, the forming member 200 bends the material 19 in one or more directions. For example, the forming member 200 can bend the material around one or both of the transverse axis 213 and the longitudinal axis 214.

As shown in Figures 3 and 4A-4D, forming member 200 includes a support structure 202 and a central protrusion 210. According to various embodiments, support structure 202 extends across at least a portion of path A of stock material 19. (Figures 1A-1C and 2A-2C illustrate path A, with the material following the path, while Figures 3 and 4A-4D illustrate path A without the material being shown.) For example, the support structure may extend transversely across the path or generally parallel to axis 213 (which is generally perpendicular to longitudinal path A). Because path A can be curved, axis 213 may also be perpendicular to every point along path A between feed station 13 and inlet 70. Support structure 202 is any suitable structure that can support the forces generated by stock material 19 drawn from feed station 13 into inlet 70. Specifically, support structure 202 can redirect stock material 19 as it passes through support structure 202.

According to some embodiments, support structure 202 may be a rod as shown in Figures 3 and 4A-4D. As shown, the rod may be generally cylindrical, forming a rod, but in alternative embodiments, the rod may have other shapes suitable for supporting and shaping the feedstock along its path. Support structure 202 may extend between transverse ends 211 and 212. In some examples, the rod may be curved, but in preferred examples, the rod is generally straight. In various embodiments, ends 211, 212 may be free (i.e., not connected to any other structure). Free ends 211, 212 may allow feedstock of sufficient width to be curled around the free ends. This configuration also allows the feedstock to be curled before entering/being pulled through inlet 70. In various examples, free ends 211, 212 are rounded, allowing the feedstock to pass through support structure 202 without snagging or tearing.

In some embodiments, the stock material 19 can slide on the forming member 200 without depending from the free ends 211, 212 (i.e., the forming member 200 is wider than the lateral width of the stock material 19, and the support structure 202 extends across at least the entire width of the stock material). In other embodiments, the stock material 19 can slide on the forming member 200 while depending from the free ends 211, 212 (i.e., the forming member 200 is narrower than the lateral width of the stock material 19, and the support structure 202 extends across less than the entire width of the stock material 19). According to these examples, the forming member 200 is wider than the inlet 71. Thus, the forming member 200 begins with a substantial curl, which is further contracted by the inlet 71 as the stock material passes therethrough. According to various examples, the forming member 200 is approximately 2 to 8 times wider than the inlet 71. Preferably, the forming member 200 is approximately 4 times wider than the inlet 71.

As shown in Figures 3 and 4A-4D, the forming member 200 may also include a central protrusion 210 extending away from the support structure 202. The central protrusion 210 is positioned on the support structure 202 in a manner that causes the stock material 19 to bend about a longitudinal axis (e.g., axis 214) as it moves across the forming member. This bending about the longitudinal axis is referred to as longitudinal bending. The longitudinal axis (e.g., axis 214) is an axis that extends parallel to the material path A at any particular point located along or near the center of the central protrusion 210. When the stock material 19 is bent about the transverse axis 213, it should be noted that the path A is not necessarily linear. However, the path A can be defined by a series of longitudinal axes that follow the path A (i.e., are parallel to and tangential to the path). As the path A bends, the direction of the longitudinal axis (e.g., axis 214) can change while remaining parallel at each subsequent point along the path. The longitudinal axis can also remain substantially perpendicular to the transverse axis 213. As used herein, the term "perpendicular" applies both when the longitudinal and transverse axes intersect and when they are inclined relative to each other. Thus, the central protrusion 210 can bend the stock material 19 about the longitudinal axis, while the support member 202 can bend the stock material about the transverse axis. The transverse bending can guide the stock material at the inlet 70, while the longitudinal bending can begin to curl the material before it enters the inlet 70. This pre-curling action can limit the possibility of the inlet 70 tearing the stock material 19 as the stock material 19 is crumpled and reduced in size by passing through the inlet 70.

According to various embodiments, the relationship between the support structure 202 and the central protrusion 210 can be such that the central protrusion 210 protrudes deeper into the stock material 19, thereby forming a longitudinal bend around the central protrusion 210. According to various embodiments, the central protrusion extends radially from the support structure. This radial extension can be in a single direction, as shown in Figures 3 and 4A-4D, or in multiple directions, or it can extend all the way around (i.e., 360° around) the support structure 202 and away from the support structure.

Depending on the embodiment in which the radial extension extends in a single direction or in a limited range of directions, the central protrusion may be a single outwardly extending post, an outwardly extending wall, or a structure extending outward in multiple directions. By way of example, as shown in Figures 4A-4D, central protrusion 210 is a transverse wall extending from support structure 202. As shown, the transverse wall is a semicircular protrusion. In various examples, the axis 215 of the semicircular protrusion is inclined but perpendicular to transverse axis 213. When longitudinally curved about this axis, this axis may also define longitudinal axis 214 or some portion of the longitudinal axis. As described above, in one example, the radial extension may be a single post having a negligible width compared to the width of support structure 202. However, in such an example, this width is sufficient to prevent the feedstock from being torn or cut by the post. In other examples, the width of the transverse wall extending from support structure 202 may be between approximately 1/4 and 1/2 of the length of support structure 202. Preferably, the width of the transverse wall extending from support structure 202 may be between approximately 1/3 and 1/2 of the length of support structure 202. Within this range, the wall may allow for a smooth longitudinal bend in the feedstock 19 , which allows for smoother receipt of the feedstock into the inlet 70 .

Typically, the shaping member 200 manipulates the path of the stock material in a manner that causes the stock material to begin to bend or curl before being drawn into the inlet member. While the support structure 202 can form the lateral curve and the central protrusion 210 can form the longitudinal curve, the combination of the two can begin to bend or curl the stock material and guide it toward the inlet 70 to begin converting the stock material 19 into the gasket material 21.

As mentioned above, various raw material products can be used. However, the central protrusion 210 can be configured to form a longitudinal bend that is suitable for minimizing tearing when entering the inlet 70. Depending on the width or rigidity of the raw material 19, the central protrusion 210 can have different lengths. In one example, the distance PH that the central protrusion 210 extends away from the forming member is between about 1/10 and 1/2 of the length of the support structure. A conversion system that processes narrower raw materials (e.g., 15 inches wide) can be closer to 1/10 to 1/4 of the length of the support structure, while a conversion system that processes wider raw materials (e.g., 30 inches wide) can be closer to 1/8 to 1/2 of the length of the support structure 202. Some conversion systems can process wider raw materials and narrower raw materials. In these systems, PH can be between 1/10 to 1/4 of the length of the support structure 202, or more preferably about 1/8 of the length of the support structure 202.

The central protrusion 210 can be generally centrally located in the path of at least one of the feedstock 19 or the support member 202. Preferably, the support member 202 is also centrally located in the path of the feedstock 19 as the feedstock flows longitudinally downstream from the supply station 13 to the inlet 17. According to various embodiments, the central protrusion 210 also extends generally away from the drive mechanism 250 and the source of the feedstock (e.g., the supply station 13). For example, the central protrusion 210 extends rearward from the support member 202 at an angle θ. In one embodiment, θ is approximately 15° to 75° relative to a horizontal plane passing through the central axis of the support structure 202. Preferably, θ is approximately 35° to 55° relative to a horizontal plane passing through the central axis of the support structure 202. More preferably, θ is approximately 45° relative to the central axis of the support structure 202. At this angle, the feedstock engages the central protrusion symmetrically from both the supply side and the inlet side. This allows for uniform forces to be generated between the forming member and the feedstock, forming longitudinal and transverse bends, and allowing the feedstock to extend from the forming member in both directions (i.e., upstream and downstream).

According to various embodiments, the shaping member 200 is located upstream of the inlet 70. The raw material can generally flow unimpeded between the two devices. In some embodiments, a space can be included between the two devices to keep the user's hands and fingers out of the system. The two devices can be directly connected to each other, they can both be connected to the support 12, or one or both can be cantilevered from the drive mechanism 250. In one example, the inlet 70 can be connected to the support 12 as described above, and the shaping member 200 can be cantilevered from the inlet 70 via the connecting member 205. The connecting member 205 can directly connect the inlet 70 and the shaping member 200. In one example, the inlet includes a coupling bracket 77 that is coupled to the connecting member 205. The connecting member 205 can set the distance between the two devices. The distance is preferably a distance that allows continuous curling from the shaping member 200 to the inlet 70 to allow a smooth transition of the raw material 19 through the inlet 70 (i.e., limited or no tearing).

For example, the supply station 13 can be any suitable surface for holding the stock material 19 in a single bundle, multiple daisy-chain bundles, a flat configuration, or a curved configuration. In various examples, as shown in Figures 1A-1C, the supply station 13 is a cart 34 that is independently movable relative to the liner conversion machine 100. In various examples, as shown in Figures 2A-2C, the supply station 13 is mounted to the liner conversion machine 100 in a basket or similar support. For example, the supply station 13 can be mounted to the liner conversion machine 100 via a support portion (such as a bracket 12). In such an embodiment, the liner conversion machine 100 and the supply station 13 do not move relative to each other. In other embodiments, the supply station 13 and the liner conversion machine 100 can be fixed relative to each other but not mounted to each other, or the supply station 13 and the liner conversion machine 100 can move relative to each other when mounted together. In any case, the supply station can support the stock material 19 in one or more units. Fig. 1A-1C shows a supply station 13, which supports multiple raw material units such as raw material units 300a, 300b, 300c, 300d, 300e and/or 300f. Fig. 2A-2C shows a supply station 13 supporting a single raw material unit 300. However, it should be noted that the support member 220 can support multiple units and/or the cart 34 can support a single unit. Each of the raw material units 300a, 300b, 300c, 300d, 300e and/or 300f can be placed in the supply station 13 individually and can be connected together after placement subsequently. Therefore, for example, each of the raw material units 300a, 300b, 300c, 300d, 300e and/or 300f can be appropriately sized to facilitate the operator to lift and place it. Moreover, any number of raw material units can be connected or connected together in a daisy chain. For example, multiple raw material units can be connected together or connected in a daisy chain to produce a continuous material supply.

As described above, the liner conversion machine can include a feed station (e.g., feed station 13 (Figures 1A-1C)). For example, each stock unit 300 can be individually placed into the feed station and can subsequently be connected together after placement. Thus, for example, each of the stock units 300a-300e can be appropriately sized to facilitate an operator's lifting and placement. Moreover, any number of stock units can be connected or daisy-chained together. For example, connecting or daisy-chaining multiple stock units together can produce a continuous supply of material. The continuous sheet can be repeatedly folded in opposite directions along transverse fold lines to form sections or faces along the longitudinal direction of the continuous sheet, so that adjacent sections can be folded together (e.g., accordion-shaped) to form a three-dimensional body of each stock unit 300.

The stock unit may include one or more straps that can secure the folded continuous sheet (e.g., to prevent it from unfolding or expanding and/or to maintain its three-dimensional shape). For example, the strap assembly 500 can be wrapped around the three-dimensional volume of the stock unit, thereby securing multiple layers or sections together (e.g., formed by accordion-like folding). The strap assembly 500 can facilitate storage and/or transportation of the stock unit (e.g., by retaining the continuous sheet in a folded and/or compressed configuration).

For example, wrapping the three-dimensional body of the feedstock unit 300 and/or compressing together the layers or sections of the continuous sheet defining the three-dimensional body can reduce its size when storing and/or transporting the feedstock unit 300. Furthermore, compressing the sections of the continuous sheet together can increase the stiffness and/or hardness of the three-dimensional body and/or can reduce or eliminate damage to the continuous sheet during storage and/or transport of the feedstock unit 300.

In general, the strip assembly 500 can be positioned at any number of suitable locations along the lateral dimension of any feedstock unit 300. In the illustrated embodiment, the strip assembly 500 is located on opposite sides of the unit. In some embodiments, as shown in Figure 6, another feedstock unit can be placed on top of each feedstock unit, wherein feedstock unit 300a is shown on top of feedstock unit 300b so that the bottom section and/or portion of the continuous sheet of feedstock unit 300a contacts the exposed portion of feedstock unit 300b. In general, the feedstock units can be similar or identical to each other. Moreover, a connector including a joining member of feedstock unit 300a can be attached to feedstock unit 300b. For example, the connector adhesive layer of the connector attached to feedstock unit 300b can face outward or face upward.

Furthermore, as described above, feedstock unit 300b can be identical to feedstock unit 300a. For example, feedstock unit 300b can include a connector that can be oriented so that its adhesive faces upward or outward. Thus, an additional feedstock unit can be placed on top of feedstock unit 300b, thereby connecting a continuous sheet of feedstock unit 300b to a continuous sheet of another feedstock unit (e.g., feedstock unit 300a). In this manner, any suitable number of feedstock units can be connected together and/or daisy-chained to provide a continuous feed of feedstock to the liner converter.

In some embodiments, as described in detail above, the feedstock unit 300 can be curved or have an arcuate shape. For example, feedstock unit 300e can be curved while feedstock unit 300a is flat. In some examples, all units are curved, or in other examples, no unit is curved. In the embodiment shown in FIG6 , feedstock units 300a-d include coupling members 400a-d. Feedstock units 300a-d can be curved so that the connector of coupling member 400a protrudes outward relative to the other parts of feedstock units 300a-d. Coupling member 400a is configured to connect feedstock unit 300a to feedstock unit 300b in a daisy chain. Coupling member 400b is configured to connect feedstock unit 300b to feedstock unit 300c in a daisy chain. Coupling member 400c is configured to connect feedstock unit 300c to feedstock unit 300c in a daisy chain. Coupling member 400d is configured to connect feedstock unit 300d to feedstock unit 300e in a daisy chain. In some examples, the stock unit can be bent after being placed in the supply station 13 (e.g., the supply station can include an anti-slip mechanism 160 as described above). Stacking or placing another additional stock unit on top of the bent stock unit can facilitate contacting the adhesive layer of the connector with the continuous sheet of the additional stock unit. After the additional stock is placed on top of the lower stock unit, the additional stock unit can conform to the shape of the lower stock unit. The conformity can be complete (i.e., the upper unit can completely adapt to the shape of the lower unit) or the conformity can be partial (i.e., the upper unit slightly adapts to the lower unit, but remains flatter than the lower unit).

The strip assemblies 500 may be spaced apart from each other along the transverse direction of the three-dimensional body of the material unit. For example, the strip assemblies may be spaced apart from each other so that the center of gravity of the three-dimensional body is located between the two strip assemblies 500. Alternatively, the strip assemblies 500 may be spaced equidistant from the center of gravity.

As described above, stock units 300a-e (or in some embodiments, a single stock unit 300) can be placed into a liner conversion machine 100 to form a liner system 50. Additionally or alternatively, multiple stock units (e.g., similar or identical to stock unit 300) can be stacked on top of each other in the liner conversion machine. A stock unit can include one or more strip assemblies 500. For example, the strip assemblies 500 can remain wrapped around the three-dimensional body of the stock unit after placement and can be removed later (e.g., the strip assemblies 500 can be cut at one or more suitable locations and pulled out).

Furthermore, it should be understood that, in general, the three-dimensional bodies of any stacked material units described herein can be stored, shipped, used in a dunnage conversion machine, or a combination thereof without any wrapping (or strapping) or with more or different straps or wrappings than the strap assemblies discussed herein. For example, twine, paper, shrink wrap, and other suitable wrapping or strapping materials can secure together one or more sheets that define the three-dimensional body of any stock unit described herein. Similarly, the methods and structures described above for supporting the three-dimensional body of the stock unit can facilitate wrapping the three-dimensional body with any number of suitable wrapping or strapping materials and/or devices. Further details of the strap assembly 500 and the daisy chain coupling element 400 are disclosed in application Ser. No. 15/593,007, filed concurrently with the present application, entitled "Stock Material Units For A Dunnage Conversion Machine," which is incorporated by reference in its entirety.

By utilizing the strap assembly 500 or similar ribbon-like wrap, the feedstock unit 300 is not forced into a laterally rigid configuration. The strap assembly 500 thus allows the feedstock unit 300 to be laterally flexible or without laterally rigid support, thereby allowing the feedstock unit 300 to bow/sag or otherwise flex into a laterally non-planar configuration.

The supply station 13 is configured to receive fan-fold stock material 19 and manipulate the fan-fold stock material 19 to be retracted from the supply station 13 in a non-planar configuration. The supply station 13 is associated with the cushion conversion machine 100 such that the cushion conversion machine 100 is operable to draw the fan-fold stock material 19 from the top of the fan-fold stock material unit 300. The non-planar configuration of the stock material 19 limits the tendency of the material to blow away/run away when exposed to significant airflow. According to various embodiments, the various embodiments of the conversion station 60 disclosed herein can be combined with anti-runaway configurations of the supply station and support. According to one embodiment, as shown in FIG6 , the support structure includes a surface 165 having a curvature that defines at least a portion of a transverse bend (i.e., an arcuate portion) in the stock material unit 300. Further details of the support are disclosed in application Ser. No. 15/593,078, entitled "Wind-Resistant Fanfold Supply Support," filed concurrently with the present application, which is incorporated by reference in its entirety. For example, in addition to the anti-straightening features of the supports, the side walls 140a, 140b support and/or form other features of the cart 34. For example, as shown in FIG6 , front vertical supports/walls 142a, 142b can extend from the side walls 140a, 140b. In some embodiments, the cart 13 can also include guide rods 134 positioned to redirect the stock material 19 as it is drawn from the stock material unit (e.g., 300a) and enters the drive mechanism 250 of the pad conversion machine 100. FIG6 also illustrates a folding portion 170 for generating a partially folded continuous sheet of stock material unit 300b, according to one embodiment.

It will be understood by those skilled in the art that, according to exemplary embodiments of the present invention, it may be necessary or desirable to accumulate or discharge pads of various types and sizes. As used herein, the terms "top," "bottom," and/or other terms indicating direction are used herein for convenience and to indicate the relative position and/or direction between the parts of the embodiment. It will be understood that certain embodiments or parts thereof may also be oriented in other positions. In addition, the term "about" should generally be understood to refer to corresponding numerical values and ranges of numerical values. In addition, all numerical ranges herein should be understood to include each integer within the range.

Although illustrative embodiments of the present invention are disclosed herein, it should be understood that numerous variations and additional embodiments may be devised by those skilled in the art. For example, features of various embodiments may be utilized in other embodiments. For example, a converter having a drum may be replaced with another type of converter. Therefore, it should be understood that the appended claims are intended to cover all such variations and embodiments that fall within the spirit and scope of the present invention.

Claims (20)

1. A padding system, the padding system comprising: A padding conversion station that pulls raw material sheets from a supply station in the longitudinal direction and converts the raw material into low-density padding, the padding conversion station comprising: An import component having an external structure defining an opening that retracts when raw material is drawn in and passes through the import component; and A raw material forming member, located upstream of the inlet member and on the upstream portion of the transfer station, to bend the raw material drawn from the supply station about a transverse axis extending generally transversely to the longitudinal direction, the raw material forming member comprising: A support structure that extends in a direction substantially the same as the transverse axis and causes the material to bend about the transverse axis, and A central protrusion extends from the surface of the support structure and protrudes deeper into the curvature of the material. As the material moves longitudinally across the support structure and the central protrusion, the central protrusion causes the material to bend about both a transverse axis and a longitudinal axis that extends substantially centrally into the material in the longitudinal direction. 2. The padding system of claim 1, wherein the central protrusion extends radially from the surface of the support structure. 3. The liner system of claim 1, wherein the liner conversion station includes a drive mechanism operable to pull raw material into the inlet component. 4. The padding system of claim 3, wherein the inlet member includes a structural member defining an opening disposed between the forming member and the drive mechanism, the opening contracting the material when the raw material is drawn in and through the inlet member in the longitudinal direction. 5. The liner system of claim 1, wherein the forming member manipulates the path of the material in a manner that causes the material to begin to bend or curl before being pulled into the inlet member. 6. The padding system of claim 1, wherein the central protrusion is a semi-circular protrusion, and the semi-circular protrusion has an axis perpendicular to the lateral extension axis of the support structure. 7. The padding system of claim 1, wherein the central protrusion extends a distance from the surface of the support structure that is between 1/10 and 1/2 of the length of the support structure. 8. The padding system of claim 1, wherein the central protrusion extends from a horizontal plane passing through the central axis of the support structure along an upstream direction relative to the inlet member at an angle of 15° to 75°. 9. The liner system of claim 1, wherein the forming member is connected to the inlet member by a connecting member extending therefrom. 10. The liner system of claim 1, wherein when the raw material is drawn from the supply station and passes through the inlet member, the forming member is positioned to change the direction of the raw material. 11. The liner system of claim 4, wherein the forming member is 2 to 8 times wider than the opening. 12. The padding system of claim 1, further comprising a supply station configured to receive raw material having a raw material width. 13. The padding system of claim 12, wherein the supply station is configured to receive raw material that is wider than the width of the forming member. 14. The padding system of claim 12, wherein the span of the support structure is less than the entire width of the raw material. 15. The padding system of claim 12, wherein the span of the support structure extends beyond the entire width of the raw material. 16. The padding system of claim 14, wherein the support structure includes a lateral free end that allows material to be wrapped around the lateral free end. 17. The liner system of claim 1, wherein the liner transfer station comprises: A lateral barrier member extending from the outer structure in a direction corresponding to the lateral width of the raw material being drawn in and passing through the padding inlet, such that the lateral barrier member restricts the tendency of the raw material to wrap around the outer structure and does not significantly restrict the raw material in the upstream direction; and A drive mechanism located downstream of the conversion station receives and pulls the raw material through the gasket inlet. 18. The padding system of claim 17, wherein the lateral barrier member includes an ear that projects laterally from the padding inlet and has a height less than that of the padding inlet. 19. The padding system of claim 18, wherein at least one ear forms an attachment to the support. 20. The liner system of claim 17, wherein the conversion station further comprises a forming member located upstream of the liner inlet, the forming member being configured to manipulate the material along its path in such a way that the material begins to bend or curl before being drawn into the liner inlet.