A dunnage conversion system includes a machine for converting a stock material into a strip of relatively lower-density dunnage, a coiling mechanism for winding the strip into a coil, a taping mechanism for automatically securing a trailing end of the strip to the coil, and a coil ejecting mechanism for automatically removing the coil from the coiling mechanism. The taping mechanism includes a guide surface between an outlet of the machine and the coiling mechanism to guide the strip to the coiling mechanism and to guide tape for engagement with a trailing end of the strip and to secure the trailing end of the strip to the coil. The coil ejecting mechanism includes a lever arm that pivots to push the completed coil off the coiling mechanism.

The disclosure relates to padding articles comprising a cancellous body formed from an agglomeration of grains made from a polymer material and are bonded together in a cancellous structure. The padding articles provide thermal insulation, sound insulation, cushioning, or a combination thereof. The disclosure also relates to container systems that include the padding articles, apparatuses/methods for manufacturing the padding articles, and methods of use thereof.

A packaging material including one or more expandable layers that provide protection to contents of a packaging enclosure formed with the packaging material. The packaging material includes at least a first layer and a second layer bonded to one another. The first layer is pulled or extended in a first direction that is effective to cause the second layer to expand in a second direction. The second layer is a cut-patterned layer which creates structural strength in the packaging material when expanded.

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.

A protective packaging web is disclosed. The web includes a first film web having a plurality of extended portions including a base perimeter enclosing an open base region and an extended surface protruding in one direction from a plane defined by the first film web. The extended surface has a larger surface area than the open base region. The web also includes a second film web sealed to the first film web around a portion of the open base region to form sub-chambers on a side of the first film web opposite the protruding direction. The first film web and the second film web remain unsealed across the open base region defining regions within the sub-chambers suitable to contain a fluid volume. The plurality of sub-chambers are interconnected via one or more intra-chamber channels, allowing each of the sub-chambers to receive and release fluid in response to external pressures.

A nozzle is usable to inflate a film having two sides that form a common channel and inflatable channels. The inflatable channels are in fluid communication with the common channel. The nozzle includes a proximal end configured to separate the two sides of the film to open the common channel as the film moves in a longitudinal direction. The nozzle includes a distal end configured to permit the two sides of the film to converge as the film moves in the longitudinal direction. The nozzle includes a slot configured to direct gas transversely into the common channel to inflate the inflatable channels as the film moves in the longitudinal direction.

A conversion assembly for a dunnage conversion machine includes both a downstream pair of rotatable members and an upstream pair of rotatable members upstream of the downstream rotatable members. The downstream rotatable members include a pair of gears, and each gear has a plurality of teeth and is rotatable about a respective axis. The gears are positioned so that the teeth of one gear are sequentially interlaced with the teeth of the other gear as the gears rotate. The upstream rotatable members include a pair of feed wheels, and the gears and the feed wheels define a path for a sheet stock material from between the upstream pair of feed wheels to between the downstream pair of gears. The rate at which the sheet stock material is advanced by the feed wheels is the same as the rate at which the sheet stock material is advanced by the gears.

An expansion devise includes an unexpended slit sheet roll that is wound on a paper core that is wider than the slit sheet paper. The paper core is placed into a yoke that holds the paper in position on each side of the unexpended slit sheet material. An adjustable downward pressure is exerted on the paper core and the paper core exerts pressure on the yoke. As the paper is pulled, this downward pressure creates the friction required to enable the unexpended slit sheet to be unwind and fed while simultaneously expanding. A blank sheet is formed into a box that stabilizes slit paper sheet wound around a core member.

Methods and structures are provided for a dunnage system to facilitate efficient coupling together of supply units of pre-configured sheet stock material, such as, for example, separate units of fanfold stacks of pre-configured sheet stock material, in a manner of continuous supply with a continuous pocket extending longitudinally between the separate supply units, so that they can interact with an expander of the dunnage system without disruption as one supply unit is depleted and a next supply unit is fed through the dunnage system. Also, various methods, apparatus, and systems are provided to facilitate smooth operation of a dunnage machine of the dunnage system to reduce a tendency of the pre-configured sheet stock material to jam and to increase the tendency of dunnage product generated to reflect a desired shape and stability.

A packing material including a plurality of discrete cushioning elements and methods for making the same. The discrete cushioning elements may be cellulosic cushioning elements. A flexible linkage may connect the plurality of discrete cushioning elements in the packing material. The packing material may also include a bottom cellulosic sheet connected to a top cellulosic sheet with the plurality of cellulosic cushioning elements positioned between the top cellulosic sheet and the bottom cellulosic sheet. The packing material may also be a molded packing material that includes bonds comprising adhesive and cellulosic fibers. The adhesive and cellulosic fibers of the bonds may be dispersed between the folds of each of the cellulosic cushioning elements.