The present disclosure is directed to a web control guide for an inflation and sealing assembly of a protective packaging formation device for inflating a web material into a chain of inflated cushions. The web control guide is positioned along a material path at a transverse spacing from a first compression element and constrains a first thickness of the material path measured normal to the longitudinal and transverse directions of the material path. The transverse spacing and constrained thickness dimension are sufficiently small to prevent transverse movement of the flexible material towards the first compression element to avoid excessive heating of the web material outside a sealing zone.

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.

An exemplary air cushion inflation machine includes: a first terminal connected to a direct current input; a second terminal; a reference resistor powered by the direct current input; an op-amp; and a transistor. The first terminal of the op-amp is connected to a variable voltage source and the second terminal of the op-amp is connected to the reference resistor. The transistor has a base connected to an output of the op-amp, an emitter connected to the reference resistor, and a collector connected to a first terminal of a sealing band apparatus having first and second terminals. A meltable material placed between the first and second terminals is melted by resistance of current flowing between the first and second terminals. The variable voltage source changes voltage based on a voltage drop measured across the first and second terminals by a voltage measurement device and the constant current.

A coiler for producing tighter or smaller coils of dunnage uses a cam to move fork pins from a dunnage-receiving position inwardly to a more closely-spaced coiling position. The fork pins are coupled to pin mounts that cooperate with the cam and slots in a guide plate to move the parallel fork pins between the dunnage-receiving and coiling positions. The fork pins are mounted to extend perpendicular to and through the guide plate on opposing sides of a path of the dunnage to capture and wind a dunnage strip into a coil.

In a method for processing a cushioning material strand, which is produced by a cushioning conversion machine from a web-shaped stock material (e.g. a roll or a leporello stack, for example of paper), the cushioning material strand is wound around a winding center into a cushioning material winding and is compressed during winding into the cushioning material winding.

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.

An apparatus for the production a cushion product from a single- or multi-layer continuous paper strip includes a feed unit for drawing the paper strip into the apparatus, a cutting unit for cutting the cushion product from the paper strip, and control electronics for the activation of the cutting unit according to a predetermined motion profile. A sensor captures a rotation angle position of the feed unit. The control electronics are configured to activate the feed unit continuously and to start an activation of the cutting unit for a discontinuous cutting operation during capturing a predetermined actual rotation angle position of the feed unit.

Fiber-based composite material for padded mailers and corresponding systems and methods are provided herein. A fiber-based composite includes a fiber-based backing material and a fiber-based padding attached to the backing material to provide cushioning for items within a mailer. The fiber-based padding is applied as a plurality of tubular structures, each defining a perimeter extending from a first point of attachment to a second point of attachment. The perimeter further defines an apex point which is spaced apart both laterally and vertically from a center point on the backing material that is between the first and second points of attachment. A plane connecting the center point and the apex point defines an angle with the backing material that is greater than 5 degrees and less than 75 degrees.

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.

Disclosed herein are protective packaging stock material units that are used in a dunnage system. A dunnage system includes a dunnage conversion machine and a supply station. The supply station is a cart that includes a biased support that is connected to a vertical side support. The biased support is movable from an open position to a closed position with respect to opposing vertical side supports. In the closed position, the biased support is configured to at least partially block the opening between the opposing vertical side supports. In the open position, the biased support leaves the opening between the opposing vertical side supports sufficiently open to load fanfold stock material therein. The biased support is biased towards the closed position and the open position. The supply station also includes an alignment device forming a funnel positioned under its base. The alignment device receives a dunnage machine stand base causing the supply cart to consistently align with the stand base in response to the stand base being slid into engagement with the alignment device.