A packaging apparatus with an improved pinch roller apparatus, fluid supply apparatus, and/or a sealing apparatus. The pinch roller apparatus (e.g., comprising one or more guide and/or pinch rollers) is used to deliver film material to the fluid supply apparatus (e.g., nozzle and blower apparatus, or the like) that fills one or more chambers of the film material with fluid (e.g., air, gas, or other like fluid), and the film material is then sealed by a sealing apparatus (e.g., using one or more heating elements with an improved temperature sensor configuration) that seals the fluid within the one or more chambers in order to form the inflated article (e.g., inflated packaging material). In particular, the sealing apparatus provides improved sealing through the improved accuracy of the temperature reading in the heating zone, in part, by locating a sensor between a heating element and a protective member that covers the sensor.

A machine for converting a sheet stock material into a dunnage product includes a conversion assembly for converting sheet stock material into a dunnage product as the sheet stock material travels along a path from an upstream end of the conversion assembly to a downstream end of the conversion assembly. The machine further includes a transversely extending guide over which the stock material passes for guided entry into the upstream end of the conversion assembly. The guide is rotatable such that the transverse extent of the guide can be moved between a plurality of relatively rotated orientations to guide the sheet stock material from different sides of the conversion assembly.

A packaging apparatus with an improved pinch roller apparatus, fluid supply apparatus, and/or a sealing apparatus. The pinch roller apparatus (e.g., comprising one or more guide and/or pinch rollers) is used to deliver film material to the fluid supply apparatus (e.g., nozzle and blower apparatus, or the like) that fills one or more chambers of the film material with fluid (e.g., air, gas, or other like fluid), and the film material is then sealed by a sealing apparatus (e.g., using one or more heating elements with an improved temperature sensor configuration) that seals the fluid within the one or more chambers in order to form the inflated article (e.g., inflated packaging material). In particular, the sealing apparatus provides improved sealing through the improved accuracy of the temperature reading in the heating zone, in part, by locating a sensor between a heating element and a protective member that covers the sensor.

A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

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 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.

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 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.

A machine for converting a sheet stock material into a relatively less dense dunnage product includes both (a) a helical pre-form assembly having a cylindrical mandrel with a longitudinal axis and a guide member for guiding the sheet stock material from a supply thereof into a helical path along and around the mandrel so as to form a helical pre-form that rotates around the longitudinal axis and advances parallel to the longitudinal axis; and (b) a restriction in the path of the pre-form that slows the advance and rotation of the pre-form past the restriction, the restriction causing the pre-form to retard longitudinal advancement, to twist upon itself, and to permanently deform as it moves past the restriction, thereby longitudinally and helically crumpling the pre-form.

An inflation feature for a shipping package, an inflation rig assembly for inflating a shipping package, and a method of inflating a shipping package. The method includes providing an inflation feature and an inflation rig assembly with corresponding alignment features, positioning the inflation feature of a shipping package, in an uninflated state, on to the inflation rig assembly in a first position, moving the inflation rig assembly to a second position, such that the shipping package is in fluid communication with an expansion material source, and inflating the shipping package to an inflated state.