CA1243900A

CA1243900A - Mechanism and method for producing cushioning dunnage

Info

Publication number: CA1243900A
Application number: CA000479811A
Authority: CA
Inventors: Gary W. Ottaviano
Original assignee: Ranpak Corp
Current assignee: Ranpak Corp
Priority date: 1984-05-10
Filing date: 1985-04-23
Publication date: 1988-11-01
Also published as: US4717613A

Abstract

t MECHANISM AND METHOD FOR PRODUCING CUSHIONING DUNNAGE A cushioning dunnage producing mechanism and method wherein the mechanism utilizes one or more webs of sheet-like stock material, with the stock material being adapted to be disposed by the mechanism in generally superimposed relation and then fed into a crumpler section of tubular-like construction, to radially compress the sheet-like material into a pad-like dunnage product. The lateral edges of the stock material are caused to be rolled inwardly into generally spiral-like form, prior to passage of the stock material into the crumpler section, by a forming frame of generally triangular-like shape both in plan and in side elevation, with the nose of the forming frame being disposed closely adjacent the entranceway to the crumpler section. Meshed spur gears coacting with the crumpler section, coin or stitch the confronting portions of the rolled edges of stock material together, to hold the produced dunnage product in a pad-like configuration. The forming frame mechanism is operable to cause the central coined or stitched section of the pad-like product to be as thin a possible, while urging the stock material into the lateral pillow-like portions of the product, thereby providing greater resiliency to the pad-like product and one of lesser density.

Description

MECHANISM AND METHOD ~OR PRODUCING
CUSHIONING DUNNAGE
Specification Thi~ invention relate~ in general to mechani~m and 5 m~thod for producing packaging material or cu~hioning dunnage as it is known in the art, and mor~ particular-ly to a dunnage producing mechani.c;m operable to produce a continuous resilient pad~like dunnage product from sheet-Like material, such as paper, and wherein the 10 mechanism include~ a novel stock material forming frame resulting in a materially improved pad-liXe cushioning dunnage product, and more particularly one having a greater portion of the utilized stock materi21 disposed in the lateral pillow-like portions of the lS product, thuq providing greater resiliency to the lesser density product.
Back~round of the Invention Dunnage producing mech~nism for producing a resilient pad-like cushioning dunrlage product having 20 lateral pillow-like portions and a central connected portion are known in the art. U.S. patent 3,509,79~
dated May 5, 1970 to G. R. Johnson discloses a rnecha-nism for producing such general type of cushioning dunnage product, and a mechanism which utilizes a 25 pusher or former to cause inw~rd rolling of the lateral edges of the sheet stock material as it moves from the supply of stock into the crumpler section of the machine.
U.S. patent 3,655,500 dated April 11, 1972 to G. R.
30 Johnson discloses a cushioning dunnage product pro-ducible on, for instance ~ mechanism of the generai type of patent 3~509,798.

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U.S. patent 3,603,216 dated September 7, 1971 to G. R. Johnson relates to a method of producing re~ilient cushioning dunnage product of the general structural type discussed, but of greater density as compared to 5 the dunnage product of the present invention.
U.S. patent 3,799,039 dated March 26, 1974 to G. R.
Johnson discloses a cushioniny dunnage producing mecha-nism including a trough coacting with the crumpler section of the machine and also coacting with a pusher 10 or former mean~, for causing inward rolling of the lateral edge~ of the stock material prior to entry thereof into the crumpler section of the machine.
U.S. patent 4,026,19~ dated May 31, 1977 to Gary W.
Ottaviano discloses a cus}liolling dunnage producing 15 mechanism of the general type of the pre~ent inventlon and which includes a trian(3ul~1r ~hape, in plan, pushing or forming frame coactin~ with a chute which coact~
with the crumpler section of the machine, for forming the sheets into rolled confic3uration prior to their 20 passin~ into and thence through the crumpler section.
The forming frame in this arrangement of dunnage pro-ducing mechanism is of generally planar configuration in side elevation and as illustrated in the patent, i9 adapted to coact comparative]y closely with the inclined 25 hottom ~urface of che chute, and in substantial longi~
tudinally spaced relation from the crumpler ~ection of the mechanism.
Summary of the Invention The present invention provides a novel dunnage pro-30 du~ing mechani~m for producing from sheet-like ~tock ~aterial, such as for instance paper, a relatively ~: :

.,, :
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light weight pad like cushioning dunnage product, and wherein the mechanism i9 of the general type of appli-car.t's aforementioned prior art patent except that the pusher or forming frame has been revised and rather 5 than being generally planar in 3ide elevation, i~ of greater three-dimensional configuration in side eleva-tion, and wherein such forming frame is located close to and coacts with the crumpler section of the dunnage producing mechanism, to produce a dunnage product lO having lateral pillow-like sections o~ improved re-siliency and mass and a central connecting section of a lesser amount of the stock material, 90 that the papex stock as utilized, i~ oriented into the lateral pillow-like section~ for improvecl cushioning charac-lS teristic~.
Accordingly, an object o~ t.he invention i3 toprovide a novel mechanism for produclng dunnage or packing material.
Another object of the invention is to provide a 20 mechanism of the latter type which utilizes a plurality of webs or sheets of sheet-like material, such a~ paper, and forms ~uch webs or sheets into a pad-like cushioning dunnage produc~ possessing lateral pillow-like portion~
and a central compressed connecting section or portion, 25 and wherein the mechanism includesa stock material form-ing frame of generally triang~lar configuration both in plan and in side elevation, with such frame being operable to cause ~he stock material to be directed into the lateral pillow-like sections of the dunnage product 30 rather than orienting the same into the centxal com-pressed ~ection of the pad-like product.

~2~35~

A further object of the invention is to provide a novel forming frame for use in a dunnage producing mechanism of the type utilizing a plurality of web~
of superimposed stock material, ~uch as paper, and S causing the lateral e~ges of the webs to be rolled inwardly prior to ~he stock material ~eing 1008ely generally radially crump~ed in a crumpler section of th2 machine, whereby the later~l pillow-like sections of the pad-like cushioning dunnage product pro~uced 10 on the machine will have more re~iliency and volume as compared to the pillow-like sections of the prior art cushioning dunnage product of generally similar configuration.
. ~ still further object of the invention is to 15 provide a novel dunna~e product o~ relatively low density per unit volume in a pad-like configuration, comprising lateral pillow~ ke sections and a central compres~ed connecting section, and with the lateral pillow-like sections haYing greater resiliency and 20 volume as compared to the pillow-like sections of the prior art pad-like cushioning dunnage product pro-duced on somewhat similar type machines, and with the central compre~sed section of the pad-like cushioning dunnage product embodying a les~er mass or amount of 25 the stock material, whereby the cushioning charac-teristics of the product are improved.
A still further object of the invention is to provide a novel method of producing cushioning dunnage in pad-like form.
Other objects and advantages of the invention will be apparent from the fo].lowing description taken in ~3~

conjunction with the accompanying drawing~ wherein:

FIGURE 1 i3 a side elevational, generally diagram-matic illustration of a cushioning dunnage mechani3m 5 embodying the invention;
FIGURE 1' is a modification of the roll mounting of FIGURE l;
FIGURE 2 is a top plan view of the mechanism of FIGURE l;
FIGU~E 3 is a generally perspective view of a dunnage producing machine of FIGURES 1 and 2, taken from the fro~t end thereof, and illustrating the pad-like dunnage product being emitted by the machine, FIGURE 4 is a fragmentary view of a roll of sheet-15 like stock material adapted for use in the dunnageproducing mechanism of FIGURES 1-3;
FIGURE 5 is a fragmentary detailed view of the interior of the dunnage producing mechanism of FIGURES 1 through 3, and illustrating in particular 20 the crumpler portion thereof and the forming frame (in dashed lines) coacting therewith, for producing the improved pad-like dunnage product;
FIGURE 6 is an end view taken generally along the plane of line 6-6 of FIGURE 7, looking in the direction 25 of the arrows, of the chute member and attached crumpler section of the dunnage producing mechanism of FIGURES
1-5, illustrating in phantom lines th~ paper forming frame which is adapted to be disposed therein, FIGURE 7 is a top plan view of the chute and crumpler 30 section of the mechanism of FIGU~S 1 through 6;
FIGURE 8 is an enlarged ~ide elevational view of 39~

the forming frame and its supporting structure on the dunnage producing machine, illustrating the preferred tipped relationship of the forming frame with respect to the bottom ~urface ~illustrated with a dot-dash 5 line) of the associated chute of the dunnage producing mechanism.
FIGURE 9 is a top plan view of the forming frame and support of FIGURE 8;
~ IGURE 10 is a rear end elevational view of the 10 forming frame and associated mounting structure of FIGURE 8, taken generally along the plane of line 10-10 thereof;
FIGURE 11 is a fragmentary side ~levational vi~w of a dunnage producing machine embodying a modified 15 forming frame as compared to that illustrated in FIGURES 1 to 3, and illustrating the frame nose e~tending into the crumpler section of the mechanism;
FIGURE 12 is a fragmentary top plan view of the machine of FIGURE 11;
FIGURE 13 is a fragmentary top plan view of a modified further embodiment of dunnage producing mechanism as compared to the above first and second embodiments and wherein the chute has been eliminated from the dunnage producin~ mechanism and the crumpler 25 section has been modified to llave a widely flared entrance mouth, FIGURE 14 is a broken fragmentary side ele~ational : view of the embodiment illustrated in FIGURE 13, FIGURE 15 is a fragmentary, broken illus ration of 30 a still further embodiment of wide flared crumpler SeCtlOn and coacting~forming frame, with the nose of : :

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the frame extending into the crumpler section and in coacting relationship with the flared entrance mouth thereof:
FI~URh 16 is a fra~ment~ry top plan view of a 5 further embodiment of crumpler section having a much smaller flared entrance mouth, with the forming frame and an associated stock guide coacting with such crumpler section, FIGURE 17 i~ a fragmerltary side elevational view 10 of the F~GURE 16 embodiment, FIGURE 17' is a view generally similar to FIGU~E
17 but illustrating a further embodiment wherein the nose of the forming frame extends into the crumpler section in a generally similar manner as in the 15 FIGURE ll e~bodiment;
FIGU~E 18 is a perspective illustration of a section of pad~like dunnage product produced by prior art dunnage producing mechanism aforediscussed in the background of the invention section of this 20 application; and FIGURE l9 is a perspective illustration of pad~like dunnage product produced by the mechani~m of the present invention and illustrating the gxeater volume of the lateral pillow-like sect.ions Z5 thereof, and the lesser thickness central connecting section of the lesser density pad-like product.
Description_of Preferred Embodiment : : And Alternate Embodiments Referring ~ow again to the drawing~, there i~
30 illu~trated a dunnage producing machine 10 (FIGURES :

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1, 2 and 3) which utilizes a single multi-ply stock roll 12 of sh0et like material such as, for instarlce thirty-pound Kraft paper. In the embodi-ment illu~trated, the stoclc roll 12 comprises a 5 hollow core 14 of generally cylindrical con-figuration on which are rolled three superimpo~ed webs or runs 16, 17 and 18 of paper stock material.
The roll of stock material is adapted to be mounted on a supporting rod 19 extending through core 14, 10 for rotation of roll 12 relative to the support structure 20, as the paper stock is drawn into the dunnage machine 10.
Open top, upstanding U-shaped guides 22 are pro-vided in the embodiment illustrated, ~or generally 15 loo~ely receiving the ends of the rod 19 and retain the rod on the support structure 20 while providing for rapid replacement oE the stock roll whsn necessary. In the embodiment illustrated, the three superimposed web~ 16, 17 and 18 of paper 20 stock are of generally equal width. ~s an exampla, the elongated roll of stock material mounted on the machine may be of a dimension of approximately 9 inches in diameter by approximately 28 to 30 inches in width.
One end of the rod 19 ex~ending through the stock roll, i~ adapted to have an opening there-~: ~: through receiving a pin projecting Iaterally from : the rod, for preventing rotation of the rod upon rotation o the roll about rod 19. In other words, 30 the roll of stock frictionally rotate~ rel~tive to ;

~2~3~
g the rod 19 during pulling o~ t}-e stock material into the dunnage producin~ mechanism in the embodiment illu~trated.
Machine 10 comprises, in the embodimellt 5 illu~trated, a support frame 24, inclucling leg portions 24a which preferahly include mean~ 25 a~sociated therewith for leveling the support frame with re~pect to the supporting surface S.
Frame 24 in this embodiment support~ a longitudi-10 nally converging chute 26 (FIGU~ES 1, 2 and 6~ which chute forms a guide for the webs of stock material 16, 17 and 18 as they are drawn off the stock roll 12 and are passed to a longitudinally elongated tunnel-l~e crumpler section 28 o~ t}-e dunnage producing 15 machine. In the embodiment illustrated, the chute 26 and the cxumpler section 2B may be provided a~ an integral unit which can be conveniently ormed of, for instance, fiberglass or plastic or some other uch suitahle material (FIGURES 6 and 7).
A~ can be bffst seen in FIGURES 1, 2 and 6, the ~: chute section 26 comprises a widened mouth or .
entranceway 30, with the upper, lower and side wall : interior surfaces 32, 3~, 34a (FIGURE 6~ of the chute:converging forwardly with respect to one Z5 another and with respect to the entranceway.
: ~ Entranceway 30 is of general1y oval configuration (FIGURE:6j, with the major:ax~is X-X of the oval ; : shape preferably disposed in a generaIly horizontal plane which passes through the llorlzontal center :~
~ 30 plane of the crumpler seetion 28. The mInor aXiS

... ~ ~ .

' ' .

'~Z~9~ `

Y-Y of the oval shaped entranceway is preferably dispoqed in a vertical plane passing through the longitudinal center axi~ of the crumpler section 28.
The top wall of the chute may be recessed a~ at 36 5 (FIGV~ES 2, 6 and 7) for providing accessibility to the interior of ch~te 26 for mounting stock forming frame 40, with which the present invention is particularly concerned.
Forming frame 40 ln the embodiment illustxated, 10 is formed of preferably round me~al bar stock material, and comprises an upper body portion 41 of generally V-shape, in plan, (FIGU~E 9), with depend-ing generally U-shaped, in end elevation, rib~ 41a, 41a' and 41a" extending transverse of the body 15 portion 41 and connected as by means of welds.
Accordingly, the overall frame presents a yenerally triangular external shape in plan (FIGU~ES 1 and 93.
Since the transverse ribs 41a, 41a', 41a" decrease generally uniformly in depth from the rearwardmost 20 rib 41a in a direction toward the forwardmo3t rib 41a"~ the frame 40 also presents a generally tri-angular external shape in side elevation (FIGURE 8).
The frame 40 may be conveniently formed by bending the bar ~tock downwardly as at 43 (FIGUR~S 8, 9 and 10) 25 at ~he rearward end of the bocly portion of the frame, to pxovide the aforementioned rearwardmost generally U-shaped (in end elevation) rib portion 41a which projects (as do the okher welded ribs3 generally pexpendicular out of the plane of the upper body 30 portion 41 of the fxame.

39~

As can be seen, the $orming frame ~0 i9 gupport:ed in depending relationship from generally horizontal strap 44 which is attached by any suitable means to the support frame 24 of the dunnage produci~g S machine. ~anger~ 46 depending fxom strap 44 and extending through slot 36 in chute 26 are secured as by means of threaded ~ds to complementary threaded sockets 48 secured to the rearward and forward U-shaped ribs 41a and 41a" respectively of 10 the forming frame. The length of hangers 46 can be adju~ted with respect to support strap 44 by means of threaded portions 49 and coacting nuts 50, so that the position of the frame 40 relative to the bottom surface 34 of the chute 26 and the crumplar 15 section 28 can be selectively varied. Elongated slots 52 in strap 44 provide for ad]ustment of the frame 40 longitudinally thereof relative to the chute 26 and the crumpler section 28.
A~ can be best seen in FIGURES 1, 2 and 8, in 20 this embodiment, the forming frame 40 is so pro-portioned and positioned with respect to the crumpler section 28, that the nose 54 of the frame 40 i9 disposed in close adjacent relation ship to the entrance mouth 56 of the crumpl~r 25 section 28 (~IGURES 1 and 2) and also, in this em~odiment, in closely spaced relatiorlship to the confronting surEace 34 of the chute section 26, as best illu~trated in FIGURE 8. In this embodim~nt of machine, this spacing Z of the nose portion 54 30 from the confronting surface 34 of the chute 26 ~%~3~
~ 12-adjacent its juncture with crumpler section 28, i~
preferably between approximately one sixteenth to one-eighth of an inch.
The rear U-shaped r.ib 41a of the forming frame 5 40 as can be best seen in FIGURE 8, is spaced a considerable greater distance from the su:rface 34, and in the e~bodiment illustrated, a distance of prefexably approximately four to five inches from confronting surface 34 of ~he chute section 26.
10 This may be accomplished by adjusting the associated supporting rod~ 46 by mean~ of the thread-ed nuts S0, to provide the aforediscussed pxeferable clearances between the forming frame 40 and the con-fxonting interior surface of the chute section.
lS With such orientation, the frame 40 will be tilted at an angle X of approximately 3 to 6 with respect to the horizontal, which i 9 the preferable range of tilt.
The frame 40 c~uses the sheet-like s-tock material a~ it passes from the stock roll 12 to the crurnpler 20 section 28, to be inwardly rolled along the lateral edges thereof, with the chute section 26 in this embodiment contributing a generally guiding function to the webs of stock matexial, and with the stock material 31idin~ past the frame 40 in en~aged 25 relatio~ therewith, and being urged laterally or dcwnwardly as the web stock material pa~ses from the~stock roll 12 through the machine's separating means 60 and then past the forming frame into the crumpler ~ection.
Separating means 60 in the embodiment illustrated, .

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comprises a plurality of vertically spaced bar-like or rod-like elements 60a 60b and 60c (FIGURES 1 and 23 through which i6 adapted to pass the webs of stock from the stock roll 12. As can be best seen S from FIGURE 1 the upper web 16 of stock rnaterial is adapted to pass over the separator rod 60a while the middle web 17 passes over the separator rod 60b and the lower web 18 passes over the lawer separator rod 60c. Such separator mechanism cau~es 10 the webs to be maintained in .~eparated condition prior to their being urged back into generally juxtaposed condition at the forminq frame 40 the latter being disposed downstream from the cylindrical séparator rods and generally upstream from the ~15 crumpler section 28.
~ he lateral edges of the webs 16 17 and 1~ of the stock roll 12 after they pass the transversely extending separating rods 60a 60b and 60c~ commence to ~e turned inwardly by the engagement of the orm-20 ing frame on the underlying qenerally abutting websof stock material. Thus when the rolled lateral : edges of the webs reach the narrowed entrance mouth 56 of the crumpler sect.ion 28 they have : : been rolled inwardly into generally abutting con-25 fronting relation Witll one another and then the : webbed stock material is crumpled radially inwardly by:the crumpler section and then is coined or joined along the central portion thereof ~y the : motor powered meshed gears 62 64 comprising the ~30 connecting or stitching means for the mechani~m.

9~9~

Reference may be had to aforementioned patent 4,026,198 which describes in detail the connecting or stitching means of the mechanism.
The positioning of the frame nose 54 close to the entrance mouth 56 to the crumpler section and to the bottom surface of the chute section adjacent the juncture of the chute and crumpler sections, ensures that the material of the super-imposed webs 16, 17 and 18 of stock material is urge~ outwardly into the pillow-like portions 66 (FIGURE 19) of the formed pad-like product P and is not disposed in the compressed central section 68 of the pad-like product, thereby giving the pillow-like portions 66 greater dimension and resiliency, with the central connected section 68 of the pad-like product being composed of relatiuely minimum layers of connecting stock material, as coined by the meshed gears 62,64 of the connecting means. This produces a pad-like product P of greater resiliency and greater cushioning capacity and less density as compared to the prior art pad-like product Pl (FIGURE 18) produced on a dunnage producing machine of the type illustrated in afore-mentioned U.S. patent 4,026,198 or U.S. patent 3,509,798.
The produced product P results in a dunnage pad having a density of approximately .6 to .7 pounds per cubic foot in the un-compressed condition of the produced pad-like product, util-izing thirty-pound Kraft paper as the stock materiai.

pg/S
: ~ 14 _ .
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=15-The forming frame 40 also urges the webs of stock material into engagement with one another along the longitudinal center sections thereof during the inward rolling of the lateral edges of 5 the we~s~ and aids in maintaining alignment of the web~ed stock material in its movement from the supply roll 12 toward the crumpler section 280 After passing from the exit opening 70 o~ the crumpler section 28, the continuously formed pad-10 like product P ~FIGURES 1 and 3) of stock materialmay be severed by a cutter m~chanism 72 mounted on the rear e~d of the machine at the exit opening 70 therein. The cutter mechatlism 72 may be of the type disclosed in aforementioned patent 4,026,198 15 and thu~ the cutter mechanism 72 will not be discussed in detail here.
Referring now to FIGUI~ 11, there i~ illustrated another e~bodiment of ~orming frame in conjunction with the crumpler section of the dunnage producing 20 machine. In this embodiment, the forming frame 40' is of somewhat greater elongated dimension ~s com-pared to the frame 40 of the first described embodiment, so that the nose 54 of the frame 40' actually enters into and is disposed within the 25 crumpler ~ection 2~ of the machine, and does not terminate outside the entrance mouth 56 to the crumpler section. Such nose, however, is in general alignment with the longitudinal vertical plane passing~through th~ area of mesh between 30 the coining gears 62, 6~ in the crumpler section, ' ~3~

and is in relatively closely spaced relationship to the interior bottom surface of the crumpler section 28, and preferably a dimension generally similar to that aforediscussed in conjunction with S the first described embodiment. In any event, in this embodiment, as well as the first described embodiment, the nose portion 54 of forming frame 40 engages the flow of paper stock from the supply roll and causes inward rolling of the lateral ed~es lO of the stock material prior to passage of the stock material into the crumpler section~ In the embodiment illustrated, the nose portion 54 of the forming frame is disposed generally below a hori-æpntal plane passing through the mesh area of the 15 powered coining gears 62, 6~ extendin~ throu~h complementary openin~s 76 in the top and bottom walls of the crumpler section 2~.
In other respects, the dunna~e producing machine of the FIGURES ll and 12 embodiment may 20 be generally similar tv the machine of the first ` d~scribed embodiment.
Referring now ~o FIGURE 13, there is illustrated another embodiment of crumpler section 28' for A
dunnage producing machirle. In this embodiment, the 25 chute section 26 of the prior disclosed embodiments is eliminated from the machine, and the crumpler section 28' embodies a funnel-like portion 78 at its stock material receiving end, definin~ a widened mouth 8~ at the entranc~way to the crumpler section 30 28' for receiving the rolled webs of sheet-like ~2~3~

stock material to be compressed or crumpled inwardly.
In this embodiment, the forming frame 40 which may be of the general type aforediscussed and illustrated in conjunction with the first described embodiment, S is disposed closely adjacent to, but exteriorly of, the entranceway to the widened mouth of the crumpler section and with the frame 40 being pos:itioned gener-ally similar to that aforediscussed in conjunction with the FIGURES 1 through 5 embodiment, except that lO the nose 54 of the frame 40 deflects the flow of paper stocX a somewhat greater degree as compared to the FIGURES l through 5 embodiment. It will he seen therefore that the forming frame ~0 without the benefit of any chute, causes the inward rolling of the 15 lateral edges of the superimposed web.s of stock-like material as they are emitted ~y the stock roll 12 and move or are pulled by the co.ining gears 62, 64 into the crumpler section 28'~ The tilt of the pusher frame with the nose thereof pushing downwardly 20 against the superimposed web~ as they comme~ce to enter the wide~ed mouth of the crumpler section cau~es the materi~l of the webs to be directed laterally out-wardly to be formed into the resilient pillow section~
66 of the produced pad-liXe product P and generally 25 preventing the 5tock material from locating or being positioned along the central section 6fl of the pad-like product where coining of the product occurs to connect together the lateral resilient pillow-like sections. Thus the mechanism of the FIGU~ES 13 and 30 14 embodiment is adapted to provide a pad-like product of relatively light density and impro~ed resiliency ,...
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in the lateral pillow-llke sections thereof as com-pared tu the prior art pad-like product.
In other respects, the FIGURES 13 and 14 embodiment of dunnage producing machine may be generally similar 5 to that of the FIGURES 1-5 embodiment.
FIGURE 15 discloses a further embodiment of forming frame and crumpler section combination, and utilizes a orumpler section mechanism 28' generally ;imil~r to that aforedescribed in conjunction with 10 the FIGURES 13 and 14 embodiment. However in this embodiment, the stock forming rame 40' may be of ;the general type aforediscussed in conjunction with the FIGURES 11 and 12 en~odiment of dunnage produc-ing mechanism wherein the nose 54 of forming frame 15 actually enters or is disposed interiorly of the crwnpler section, rather than being disposed exter-iorly thereof. However in other respects, this embodiment of dunnage producing mechanism may be generally similar to that of the other embodiments 20 except for the distinctions afore-enumerated. The clearance between the nose portion of the pusher frame 40' of the FIGURE 15 embodiment and the confronting surface of the crumpler section 2~' is preferably generally similar to that aforedis-25 cussed in connection with the FIGURES 11 and 12embodiment of mechanism.
FIGURES 16 and 17 illustrate a still fur~her embodiment wherein the crumpler section 28'' has a lessor flair on the widened mouth portion ~8' thereof, 30 and~the forming frame 40'' coactiog with the crumpler .. .
.

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section 28'' has a guide 82 through which the nose of the frame 40'' passes and located generally adjacent the di~tal end of the frame for aiding in guiding the web~ of rolled stock material into the crumpler ~ec S tion. Guid~ 82 which in the embodiment illustrated i~ in the form of a ring (in front elevation) may be rigidly suspended from ~upport bar 44 by any ~uit-able means~ and prevents the rolled edge stock material from the possibility or liXelihood of "tearing" as it 10 enters the slightly flaired mouth of the crumpler section 28'', to be ra~ially compressed and stitched or coined together by power driven gears 62 t 64.
FIGURE 17' illustrates a modified arrangement wherein the nose 54 of the forming frame extends into 15 the mouth portion 78' of the crumpler section 28'' closely adjacent the mouth portion. Guide 82, upstream from the crumpler section and encompa~sing tha form-ing frame, aids in guiding the webs of stock material into the crurnpler section without "tearing" of the 20 stock material.
Fxom the foregoing discussion and accompanying drawings, it will be seen that the invention pro~ides a novel mechanism and method for producing compara-tively low density pad-like cushioning dunnage 25 product from web-like or sheet-like stock material, wherein the ~eans for causing inward rolling of the lateral edges o~ the sheet-like material into gener-ally rolled form prior to the passage of the sheet-; like material into the crumpler rnechanism of the machine comprises a stock forming frame mounted on 30 the machine frame and being of generally triangularconfiguration in plan, with the nose of the stock 3~

forming frame disposed closely adjacent to the entrance to the crumpler mechanism (in some instances being disposed exteriorly of the crumpler, and in some instances actually entering into the entranceway 5 o the crumpler) and wherein the web-like stock material is urged by the forming frame generally laterally as it is rolled inwardly, to be oriented or disposed into lateral pillow--like sections for the pad-like dunnage product with a minimum of stocX
10 material being disposed in the central coined section of the pad-like product, thus giving the pad-like product greater resiliency and reduced density.
The terms and expressions which have been used are used as terms of description and not of limita-15 tion, and there is no intention in the use of suchterms and expressions of excluding any equivalents of any of the features shown or described, or por-tions thereof, and it is recognized that various modifications are possible within the scope of the 20 invention claimed.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. In a mechanism for producing low density pad-like cushioning dunnage from sheet-like stock material comprising, a support, crumpler means mounted on said support and having an entry opening, and an exit opening spaced lengthwise from said entry opening, said crumpler means being adapted to receive the sheet-like stock material, means for causing inward rolling of the lateral edges of the stock material into generally rolled form prior to passage of the sheet-like stock material into said crumpler means, means coacting with said crumpler means for connecting the confronting rolled edges, resulting in a unitary dunnage product of pad-like configuration as produced from said mechanism, said connecting means including means for pulling the stock material from a supply thereof into said crumpler means, said means for causing inward rolling including a forming frame mounted on said support and disposed generally in line with said crumpler means, said frame adapted to be engaged slidingly with and to press against the sheet-like stock material, said crumpler means being tunnel-like and being adapted to cause the stock material to be generally radially compressed as it passes into and through said crumpler means, said forming frame being generally triangular shaped in plan with the forward end nose portion of the triangular configuration disposed closely adjacent to said entry opening of said crumpler means, said nose portion of said frame projecting into the path of travel of the stock material from the supply thereof to said crumpler means, to cause deflection of the stock material adjacent said entry opening.

2. In a mechanism for producing low density pad-like cushioning dunnage from sheet-like stock material comprising, a support, crumpler means mounted on said support and having an entry opening, and an exit opening spaced lengthwise from said entry opening, said crumpler means being adapted to receive the sheet-like stock material, means for causing inward rolling of the lateral edges of the stock material into generally rolled form prior to passage of the sheet-like stock material into said crumpler means, means coacting with said crumpler means for connecting the confronting rolled edges, resulting in a unitary dunnage product of pad-like configuration as produced from said mechanism, said connecting means including means for pulling the stock material from a supply thereof into said crumpler means, said means for causing inward rolling including a forming frame mounted on said support and disposed generally in line with said crumpler means, said frame adapted to be engaged slidingly with and to press against the sheet-like stock material, said crumpler means being tunnel-like and being adapted to cause the stock material to be generally radially compressed as it passes into and through said crumpler means, said forming frame being generally triangular shaped in plan with the forward end nose portion of the triangular configuration disposed closely adjacent to said entry opening of said crumpler means, and wherein said forming frame includes a plurality of generally U-shaped, in end elevation, ribs extending transverse of said frame and progressively diminishing in height from the rear end portion thereof in a direction toward said forward end nose portion thereof, said forming frame presenting a generally triangular shaped configuration in side elevation.

3. A mechanism in accordance with claim 2 wherein said forming frame is oriented in generally tipped condition with respect to the horizontal in its operative position in said mechanism, and including means for adjusting the tipped orientation of said forming frame with respect to the horizontal.

4. A mechanism in accordance with claim 1 wherein said forming frame is formed of round metal bar stock.

5. A mechanism in accordance with claim 1 wherein the rear end portion of said frame is of a greater transverse dimension as compared to the transverse dimension of said entry opening of said crumpler means.

6. A mechanism in accordance with claim 1 includ-ing means on said support upstream from said forming frame, for separating multiply sheets of stock material as the latter move from the stock material supply toward said crumpler means, and wherein said means for causing said inward rolling includes a chute having an entrance mouth disposed in confronting relation to said separat-ing means and extending lengthwise between said crumpler means and said separating means, for generally funneling said rolled edge stock material toward said crumpler means.

7. A mechanism in accordance with claim 6 wherein said chute extends continuously from said separating means to said crumpler means, the central axis of said entrance mouth of said chute being disposed substantially in a hori-zontal plane passing through the longitudinal axis of said crumpler means, with the digital end of said end nose portion being adapted to engage the stock material and cause inward rolling of the lateral edges thereof.

8. A mechanism in accordance with claim 6 wherein said entrance mouth of said chute is of gener-ally oval configuration in elevation with the major axis thereof extending in a generally horizontal plane and the minor axis thereof extending in a generally vertical plane, the latter passing through said longitudinal axis of said crumpler means, the longitudinal axis of said forming frame being disposed in said vertical plane.

9. A mechanism in accordance with claim 6 wherein said separating means comprises a plurality of generally vertically spaced bars extending trans-verse of said support and about which a respective sheet of the stock material is adapted to move in its travel past said forming frame and toward said crumpler means.

10. A mechanism in accordance with claim 1 wherein said connecting means comprises generally verti-cally spaced coining means disposed generally centrally of said crumpler means in a direction transverse of the latter and adapted to stitch confronting rolled edges of the sheet-like stock material together.

11. A mechanism in accordance with claim 10 including means movably mounting at least one of said coin-ing means with respect to the other of said coin-ing means for providing for movement of the coin-ing means relative to one another during the stitching operation.

12. A mechanism in accordance with claim 11 wherein said movable mounting means includes resilient means urging one of said coining means toward the other of said coining means, and means permitting movement of one of said coining means relative to the other of said coining means against the

13. A mechanism in accordance with claim 10 wherein said means for causing said inward rolling includes a chute having an entrance mouth into which the stock material from said supply in fed, said entrance mouth being of generally oval shape in end elevation with the major axis of said entrance mouth being disposed substantially in a horizontal plane, the last mentioned plane passing through said coining means.

14. A mechanism in accordance with claim 2 wherein the rearward end of said forming frame is dis-posed at a greater distance from a confronting stock material guide surface as compared to the distance of the forward nose end portion of said frame from said guide surface, whereby the stock material adapted to slide past said frame will be urged toward the outer lateral edges thereof during the rolling operation on said stock material so as to maintain the lateral rolled edge portions of the produced pad-like product possessing greater volume and resiliency while maintaining a minimum amount of stock material at the central connected portion of said pad-like product.

15. A mechanism in accordance with claim 1 wherein said nose end portion of said frame is disposed within a range of approximately one-sixteenth of an inch to one-eighth of an inch from an underlying stock material guide surface.

16. A mechanism in accordance with claim 1 wherein the nose end of said frame is disposed generally adjacent said entry opening to said crumpler means, upstream from said entry opening, and below a horizontal plane passing through said connecting means.

17. A mechanism in accordance with claim 1 wherein the nose end of said frame is disposed generally adjacent said entry opening to said crumpler means, slightly downstream from said entry open-ing and within said crumpler means, and below a horizontal plane passing through said connecting means.

18. A mechanism in accordance with claim 1 wherein said connecting means comprises vertically spaced rotatable meshed gears disposed gener-ally centrally of said crumpler means in a direction transverse of the latter and adapted to coin together confronting rolled edges of the sheet-like stock material, said crumpler means comprising a tunnel-like member having a rectangular shaped entrance with the greater dimension of said rectangular shape being in a direction transverse of said mechanism, said tunnel-like member having a pair of spaced openings in the upper and lower walls thereof through which extend said gears, said end nose portion of said frame disposed adjacent said tunnel-like member and in general alignment with the vertical longitudinal plane of said tunnel-like member.

19. A mechanism in accordance with claim 1 wherein the second mentioned means includes a chute upstream from said crumpler means and having an oval shaped entrance mouth, said chute and said crumpler means being integrally formed as a unit, said crumpler means being disposed in general alignment with a horizontal plane passing through the major axis of said chute entrance mouth, and the bottom wall of said chute merging with said crumpler means.

20. A mechanism in accordance with claim 3 wherein said frame is tilted at an angle of between approximately 3° to 6° with respect to the horizontal so as to locate the nose end portion of said frame projecting into the path of travel of the stock material from the supply thereof into said crumpler means.

21. A mechanism in accordance with claim 6 wherein said frame occupies in a longitudinal direction substantially the full longitudinal length of said chute with the nose portion of said frame terminating closely adjacent the entrance to said crumpler means.

22. A mechanism in accordance with claim 1 including a guide comprising the second mentioned means through which said nose portion of said frame extends, said guide being operative to aid in guiding the rolled edge stock material into said crumpler means, and aiding in preventing tearing of the stock material.

23. A forming frame for use in a mechanism adapted to produce low density pad-like cushioning dunnage product from sheet-like stock material, with such mechanism comprising a tunnel-like crumpler section having an entry opening and an exit opening spaced lengthwise from said entry opening, with said crumpler section being adapted to receive the sheet-like stock material therein and to generally radially compress it as it passes through said crumpler section, said forming frame being adapted to engage on its underside the sheet-like stock material as it travels from a source of stock material to the crumpler section and to cause inward rolling of the lateral edges of the stock material into generally rolled form prior to passage of the sheet-like stock material into the crumpler section, said forming frame including generally U-shaped in end elevation ribs extending transversely of said forming frame adjacent the lower portion thereof with said ribs being spaced longitudinally of said formimg frame, said forming frame being of generally triangular configuration in plan, with the forward end nose portion of said forming frame being adapted to be disposed closely adjacent to the entry opening of the crumpler section with said nose portion projecting into the path of travel of the stock material as it travels from the source of stock material to the crumpler section.

24. A forming frame in accordance with claim 23 wherein said frame comprises a V-like in plan body portion and with said generally U-shaped in end elevation ribs extending transverse of said body portion in depending relation and progressively diminishing in height from the rear end of the body portion in a direction toward the forward nose end of the body portion, said frame in side elevation presenting a generally right triangular configuration, while being of delta triangular configuration in plan.

25. A forming frame in accordance with claim 23 wherein said body portion and said ribs in transverse section are defined by arcuate exterior surfaces.

26. In a method of producing cushioning dunnage in pad-like form from sheet-like stock material comprising taking at least one web of sheet-like stock material of predetermined width, and moving it longitudinally while rolling the lateral edges of web inwardly into generally spiral-like form, pushing laterally on the web by means of a triangular shaped, in plan, forming frame with the nose of the frame disposed close to the entranceway to a tunnel-like crumpler section, and projecting said nose of said frame into the path of travel of said web as it moves from the supply source thereof to said crumpler section to cause deflection of the web adjacent said entranceway, and pulling the web of stock material as tensioned laterally by said frame through the crumpler section to cause said longitudinal movement of said web and radial compression of the rolled edge stock material into pad-like form comprising lateral resilient pillow-like portions, and then connecting together the confronting rolled and compressed lateral edge portions of the pad product whereby the central connecting section of the pad product is maintained as thin as possible while stock material is urged into the lateral pillow-like portions.

27. A method in accordance with claim 26 including the step of providing a plurality of webs of sheet-like material, orienting the latter into superimposed relation and pushing the webs laterally into generally tensioned relation with one another by said frame prior to radially crumpling the sheet-like material into the pad-like configuration, and utilizing connecting means to accomplish said connecting by coining of said central section.

28. A method in accordance with claim 26 wherein said frame is tipped with respect to the horizontal between about 3° to 6° to orient said frame nose close to said entranceway to said crumpler section and into the path of travel of the stock material.

29. Paper dunnage product comprising a pad-like article for use in packaging, formed from paper sheet or the like with the lateral edges of the sheet having been generally loosely rolled inwardly and forming radially crumpled pillow-like portions defining the lateral extremities of said packaging article, and means connecting the rolled confronting edges of the pillow-like portions together along the generally central portion of the pad-like article, lengthwise thereof, the last mentioned means comprising lengthwise spaced transversely extending coined portions of said paper material, said laterally arranged pillow-like portions of said article possessing considerable resiliency, each being of a substantially greater thickness than said central coined connected portion, and occasioned by said paper material having been urged outwardly into said pillow-like portion of the formed product instead of remaining in said central connected portion giving said pillow-like portions greater dimension and resiliency, with said central connected portion being comprised of minimum layers of connected paper material as coined, said article having a density of approximately .6 to .7 pounds per cubic foot as compared to a density of approximately one pound per cubic foot for prior art dunnage product pad-like articles of generally similar configuration.

30. A dunnage product in accordance with claim 29 formed from thirty-pound Kraft paper.

31. A dunnage product in accordance with claim 30 wherein said article consists of three individual webs of said thirty-pound Kraft paper originally disposed in superimposed relation with respect to one another and in single roll form, and with the corresponding lengthwise edges of the plurality of webs when the latter are drawn from said roll to form said product being disposed in interleaved, inwardly rolled, radially crumpled form, providing said pillow-like portions, and wherein said high resiliency and greater dimensional size of said pillow-like portions and said minimum layer centrally connected portion are provided by having the nose of a triangular shaped in plan forming frame of a dunnage converter machine in which said product is produced extending into the path of travel of said webs from the source of supply thereof to the coining means on the converter as the webs move from the supply source to the coining means, for causing lateral deflection of the webs at the engagement of the nose with the webs before passage of the webs into the coining means.

32. In a method of producing cushioning dunnage in pad-like form from sheet-like stock material comprising taking at least one web of sheet-like stock material of predetermined width, and moving it longitudinally by means of a pair of coacting rotatable members while rolling the lateral edges of web inwardly into generally spiral-like form, pushing laterally on the web by means of a triangular shaped, in plan, forming frame with the nose of the frame disposed upstream from said coacting members but generally close to the latter and projecting said nose of said frame into the path of travel of said web as it moves from the supply source thereof to said coacting members, to cause deflection of the web generally close to said coacting members and including pulling the web of stock material by the rotation of said coacting members, while the stock material is tensioned laterally by said nose of said frame, to cause said longitudinal movement of said web and formation of the rolled edge stock material into pad-like form comprising lateral resilient pillow-like portions, and then connecting together the confronting rolled edge portions of the pad-like form by stitching the central lengthwise extending section of the pad-like form utilizing said rotating coacting members whereby the central connecting section of the pad-like form connecting said pillow-like portions together is maintained as thin as possible while stock material is urged into the said lateral pillow-like portions.