A dunnage conversion machine (36) converts a sheet stock material into a dunnage product that is relatively thicker and less dense than the stock material, but is relatively thin and sufficiently flexible to function as a protective wrap. The conversion machine includes a feed mechanism (40) that advances a sheet stock material therethrough and a connecting mechanism (42) downstream of the feed mechanism. The connecting mechanism retards the passage of the sheet stock material therethrough by feeding the stock material therethrough at a slower rate than the feed mechanism feeds the stock material to the connecting mechanism. This causes the stock material to randomly crumple in a longitudinal space between the feed mechanism and the connecting mechanism. The connecting mechanism connects multiple overlapping layers of sheet stock material together as they pass therethrough, including connecting at least one crumpled sheet to one side of one other sheet.

The invention relates to a method for producing a cushioning product (88), comprising the following steps: providing a flat, longitudinal, two- or multilayered paper strip (10), wherein the individual layers (12, 14) of the paper strip (10) are connected to one another in at least some sections in a middle area (18) extending in the longitudinal direction, and wherein the individual layers (12, 14) of the paper strip (10) comprise marginal areas (20, 21, 22, 23) which are not connected to one another, opening adjacent marginal areas (20, 21, 22, 23) to form a paper strip (10) having a star-shaped cross section, and crumpling the paper strip (10) along the middle area (18).

A dunnage conversion machine (36) converts a sheet stock material into a dunnage product that is relatively thicker and less dense than the stock material, but is relatively thin and sufficiently flexible to function as a protective wrap. The conversion machine includes a feed mechanism (40) that advances a sheet stock material therethrough and a connecting mechanism (42) downstream of the feed mechanism. The connecting mechanism retards the passage of the sheet stock material therethrough by feeding the stock material therethrough at a slower rate than the feed mechanism feeds the stock material to the connecting mechanism. This causes the stock material to randomly crumple in a longitudinal space between the feed mechanism and the connecting mechanism. The connecting mechanism connects multiple overlapping layers of sheet stock material together as they pass therethrough, including connecting at least one crumpled sheet to one side of one other sheet.

An apparatus for providing packaging material (e.g. a corrugated board web section or a paper cushioning material strand) by manipulating (e.g. deforming, conveying and/or separating) a fiber starting material (e.g. a single or multi-ply paper web or a corrugated board web) may include at least one working device to be driven mechanically by at least one electric motor having a stationary stator and a rotor mounted movably thereto. An excitation current may be applied to a coil arrangement of the rotor or of the stator. The motor may be free of an electrical contact coupling for transmitting the excitation current between the stator and the rotor, and may include a detector to detect the position of the rotor. The working device may be a deformation device (e.g. a pair of deformation wheels), a conveyor (e.g. a pair of conveyor wheels), or a separating device (e.g. a rotary or translational cutter).

A dunnage crumpling apparatus is provided having first and second entry-side crumpling members and first and second exit-side crumpling members. The first and second entry-side crumpling members define an entry therebetween. The first and second exit-side crumpling members define an exit therebetween that is disposed along the longitudinal path downstream of the entry. A crumpling zone being defined between the entry and exit. The first entry-side crumpling member is configured for moving at an first rate and is associated with the second entry-side crumpling member for moving sheet material through the entry in a first direction along a longitudinal path at an entry rate. The first exit-side crumpling member is configured for moving at an second rate and is associated with the second exit-side crumpling member for moving the sheet material through the exit in the first direction along the path at a exit rate that is slower than the entry rate to crumple the sheet material for producing dunnage. The entry and exit-side crumpling members are displaced laterally along the path with respect to each other to cause shearing of the sheet within the crumpling zone.

An apparatus for forming paper dunnage from rolled paper web includes a frame, a paper trough connected to the frame for supporting and retaining a paper roll, and a crumpling mechanism connected to the frame for drawing and receiving the paper web from the paper roll and crumpling the paper web to form paper dunnage. A paper guide is connected to the frame for receiving and guiding the paper web intermediate the paper trough and the crumpling mechanism. The paper guide is spring biased to maintain the paper web in tension between the paper roll and the crumpling mechanism. The paper guide can be a spring biased, pivotally mounted guide bar. Alternatively, the paper guide can be a cantilevered sheet of springy material having a free end that engages the paper web.

A conversion apparatus is provided herein. The conversion apparatus includes a cutting member having an edge configured for cutting the dunnage material. The conversion apparatus also includes a biasing member that is located adjacent to the cutting member such that the dunnage material passes between the biasing member and the cutting member. The biasing member operably contacts the dunnage material thereby biasing the dunnage material against the cutting member. The position of the biasing member relative to the cutting member is such that in response to the dunnage material being retracted back into the conversion apparatus the cutting member begins to sever the dunnage material, but in response to the dunnage material traveling in the dispensing direction the cutting member does not begin to sever the dunnage material due to the relative position.

A dunnage-producing system includes a dunnage conversion machine for converting a stock material into a relatively less dense dunnage product, a supply of stock material, and a guide element. The conversion machine is rotatable about a substantially vertical axis. The supply of stock material includes a support for the stock material that is movable relative to the conversion machine, such as for replenishing the stock material. The guide element is rotatable with the conversion machine to maintain a consistent position relative to the conversion machine, thereby consistently positioning the support relative to the conversion machine to avoid tearing or jamming problems associated with an improperly aligned supply of sheet stock material.

A packing product, its use, a machine for production of the packing product, and a method of manufacture, creates a double curl, B or modified B having elastic, cushioning, form-fitting, and coherent packing properties. The B is created from a dimension-controlled strip of preferably, but not necessarily, cohesive paper having a cohesive side and a non-cohesive side, a leading end, and a trailing end. The leading edge is wound into a spiral in a first direction with the cohesive side of the dimension-controlled cohesive paper facing outward, while the trailing edge is wound into a spiral in a second direction that is opposite the first direction, with the cohesive side of the cohesive paper also facing outward. A plurality of Bs provide a clumped, cohesive mass around a packed item. The machine can produce Bs of various sizes to accommodate various sized items and/or packaging.

A dunnage-producing system includes a dunnage conversion machine for converting a stock material into a relatively less dense dunnage product, a supply of stock material, and a guide element. The conversion machine is rotatable about a substantially vertical axis. The supply of stock material includes a support for the stock material that is movable relative to the conversion machine, such as for replenishing the stock material. The guide element is rotatable with the conversion machine to maintain a consistent position relative to the conversion machine, thereby consistently positioning the support relative to the conversion machine to avoid tearing or jamming problems associated with an improperly aligned supply of sheet stock material.