The present disclosure relates generally to tension-activated, expanding articles, films, and sheets. In some embodiments, these articles, films, and/or sheets are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles, films, and sheets.

The present disclosure relates generally to tension-activated, expanding articles that include a plurality of patterned slits. At least some of the plurality of slits are multibeam slits that, when the material into which the slits are formed is tension-activated form one or more multibeams. In some embodiments, these articles are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles.

The present disclosure relates generally to tension-activated, expanding articles that include a plurality of patterned slits. At least some of the plurality of slits include curved terminal ends. In some embodiments, these articles are used as cushioning films and/or packaging materials. The present disclosure also relates to methods of making and using these tension-activated, expanding articles.

A manually-operated dunnage conversion apparatus includes a housing with an outlet opening, a supply of slit sheet stock material supported within the housing for dispensing from the outlet opening, and a pair of opposed expansion members rotatably coupled to the housing for rotation about respective, parallel expansion axes between the supply and the outlet opening. The expansion members are biased towards each other via a biasing member to provide a gripping force on sheet stock material fed therebetween to apply friction to the sheet stock material that causes the sheet stock material to expand in length and thickness as an operator pulls the sheet stock material from the outlet opening in the housing. With the possible exception of the biasing member, the apparatus may be made of paper-based products, making the apparatus recyclable, reusable, and composed of a renewable resource, as well as inexpensive to manufacture.

Exemplary embodiments pertain to a combined shipping and expansion device for shipping a roll of unexpanded slit sheet material and for expanding the slit sheet material. In some examples, the device includes: a container made with recyclable paper or board; a roll of slit sheet material wound around a core member and positioned within the container; the roll of slit sheet material having a slit pattern that forms open cells upon expansion; the core member being made with recyclable paper or board and having a length greater than a width of the roll of slit sheet wound around the core member and having protrusions that extend beyond each side of the roll of slit sheet material; a plurality of yoke members within the container, including at least one yoke member that rotatably receives a first of the protrusions and at least one yoke member that rotatably receives a second of the protrusions; and the container having a dispensing opening through which the slit sheet material wound around the core member can be extended and pulled, causing the core member to rotate relative to the yoke members via rotation of the roll of slit sheet material. The combined shipping and expansion device is made from substantially entirely recyclable paper or board materials, whereby after complete dispensing of the slit sheet material from the shipping and expansion device, the combined shipping and expansion device can be recycled in a paper recycling facility.

A dunnage conversion machine includes (i) a pair of gripping rollers configured to rotate at a first rotational speed to advance a slit-sheet material in a downstream direction; (ii) a pair of expansion rollers configured to rotate at a second rotational speed, faster than the first rotational speed, creating a stretching force on the slit-sheet material and further advancing the slit-sheet material, causing expansion of the slit-sheet material to a fully expanded state; and (iii) a pair of relaxation rollers configured to rotate at a third rotational speed, slower than the second rotational speed, reducing the stretching force and further advancing the slit-sheet material, allowing the slit-sheet material to relax to a partially expanded state. The pair of relaxation rollers (iii) also are configured to capture the slit-sheet material in the partially expanded state between a top cover sheet and a bottom cover sheet to form a dunnage pad.

An expansion device includes an unexpanded slit sheet roll that is wound on a paper core that is longer than the width of the slit sheet paper roll. The paper core is placed onto a rod member. An adjustable downward pressure is exerted on the paper core and the paper core exerts pressure on the rod member. As the paper is pulled, the downward pressure creates the friction required to enable the unexpanded slit sheet to be unwind and fed while simultaneously expanding.

A device for dispensing a roll of sheet stock material includes a first pair of rollers. The first pair of rollers is driven by an electric motor. The first pair of rollers is configured to receive expandable slit paper between the first pair of rollers. The first pair of rollers is configured to modify a force of friction applied to an outer surface of the expandable slit paper.

According to some illustrative embodiments, a protective product is provided that includes: at least one expandable slit paper sheet, said at least on expandable slit paper being expanded between opposing ends of said slit paper; a first embossed paper sheet facing said expanded slit paper sheet and a second paper sheet facing an opposite side of said at least one expanded slit paper sheet, at least one of said first embossed paper sheet and said second paper sheet being fixed to said expanded slit paper sheet at the opposing ends of said expanded slit paper sheet and thereby maintaining said expanded paper in its expanded state, said first embossed paper sheet having a plurality of embossings that increase the rigidity of said embossed paper sheet, whereby inhibiting deformation of said embossed paper sheet that is fixed to said expanded slit sheet paper.

A dunnage producing system is disclosed. The system comprises a material feed section configured to feed a sheet stock material into the system to convert it into a dunnage product. The system further comprises a drive belt having a plurality of lugs fixed on the drive belt configured to engage one or more die-cut openings in the sheet stock or roll stock material. The system further comprises one or more folding mandrels and a glue feed section. The folding mandrels capture the engaged sheet stock or roll stock material between the drive belt and folding mandrels. the glue feed section comprises a tank loaded with pre-melted adhesive material, a hose to transfer the post melted adhesive materials, and a dispensing nozzle to pump the melted adhesive material to the sheet stock material. A controller then receives measurement information and control the functions of the system to produce dunnage product.