In accordance with a broad embodiment of the invention, a novel paper product is comprised of two or more slit sheet packing material layers, each layer having its own slit pattern design to create interlocking layers of expansion sheet packaging materials. Each layer expands to create a three dimensional open netting of cells of hexagons, and the like, and is designed to have limited nesting with its opposing layer, thereby maximizing the thickness of the combined layers as compared to nested layers. Adjacent layers have differing slit patterns and can be expanded through expander type machinery such that the expansion rates of the differing slit pattern layers can be varied to deliver the same width of exiting expanded material from each layer. Preferably the differing slit pattern produce when expanded, inclined land areas that have the same number of rows per inch, but different angles of inclination of the land areas, such that adjacent layers can interlock, that is, have a restricted amount of nesting.

The present disclosure relates generally to tension-activated, expanding articles that include single slit patterns. 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.

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 dunnage conversion system for making a coil of dunnage from a sheet stock includes a coiler, a movable dancer upstream of the coiler and interposed in a path of the sheet stock, and a controller communicatively coupled to each of the coiler and the movable dancer. The coiler is configured to wind the sheet stock, and the controller is configured to control the speed of the coiler based on the position of the movable dancer to control tension of the sheet stock upstream of the coiler. The sheet stock drawn about the movable dancer may be a slit-sheet stock having a plurality of slits configured to expand under tension applied in a feed direction. The controller may be configured to control expansion of the slit-sheet stock upstream of the coiler allowing conversion of the sheet stock into a coil of relatively less dense dunnage prior to or during winding.

In the preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns for improved features and characteristics. In some illustrative and non-limiting example embodiments, cushioning products of the present invention can include, e.g., a novel slit sheet material in combination with extensible paper employed as, e.g., a cushioning pad or as cushioning within an envelope product, wherein the cushioning product can be substantially more resilient, but, yet, e.g., thinner for better utilization of space.

The present disclosure relates generally to tension-activated, expanding articles that include compound slit patterns. 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, films, and sheets including a multi-slit pattern. 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.

In the preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns for improved features and characteristics. In some illustrative and non-limiting example embodiments, cushioning products of the present invention can include, e.g., a novel slit sheet material in combination with extensible paper employed as, e.g., a cushioning pad or as cushioning within an envelope product, wherein the cushioning product can be substantially more resilient, but, yet, e.g., thinner for better utilization of space.

In some illustrative embodiments of the present invention, a novel expandable slit paper expansion device design is provided that, among other things, avoid complications of prior systems and eliminates the crushing effect of the rollers. Among other things, the preferred embodiments provide a unique structure that provides a novel “S” shape path of the expandable slit sheet paper, such that the expandable slit sheet paper is tortuously weaved between at least two expansion rollers without being compressed there-between, in a manner that the expandable slit sheet paper follows along surfaces of the expansion rollers without pinching or compression that occurs in the background art.

An expanding machine includes a chassis, a feeding roller carrying a honeycomb paper, a guiding roller, and an expansion roller assembly including an upper expansion roller, a lower expansion roller, and a passage gap. The upper expansion roller includes upper projection assemblies that are staggered with respect to each other. Each of the projecting assemblies includes upper projecting portions and upper supporting portions that are alternate with respect to each other. The lower expansion roller includes projecting portions and supporting portions corresponding to the upper expansion roller. When the expansion roller assembly is put into rotation, the upper projecting portions correspond to the lower supporting portion, and the lower projecting portions correspond to the upper supporting portions, so that the projections that are separately arranged may pull and expand the honeycomb paper, making it not readily compress down the honeycomb paper or generating apparent compressing marking.