CA2031526C

CA2031526C - Stitching gear assembly having perforating projections thereon, for use in converter adapted to produce pad-like cushioning material and method

Info

Publication number: CA2031526C
Application number: CA002031526A
Authority: CA
Inventors: Bruno H. Baldacci; John E. Silvis
Original assignee: Ranpak Corp
Current assignee: Ranpak Corp
Priority date: 1989-05-03
Filing date: 1990-04-18
Publication date: 1994-09-20
Anticipated expiration: 2010-04-18
Also published as: EP0427834A4; JPH0645210B2; NO178019B; DE69003514T2; EP0427834A1; CA2031526A1; KR0174270B1; DE69003514D1; KR920700103A; NO178019C; EP0427834B1; WO1990013414A1; US4968291A; JPH03502671A; NO905644L; DK0427834T3; FI910017A0; NO905644D0

Abstract

2031526 9013414 PCTABS00002 A dunnage producing machine converts multi-ply paper stock (12) into cushioning dunnage (P). The machine draws in the web stock and rolls the edges inwardly. The stock passes between a pair of gear-like members (30) which mesh together to coin the material by fastening together the inwardly rolled edges. The gear-like members have projections (66) on their teeth which perforate the stock layers to assist in maintaining the product in its pad-like form.

Description

WO 90/13414 ~ 2 ~ PCr/US90/021 10 - ':

s STITCHING GEAR ASSEM8LY HAVING PERFO~ATING
PROJECTIONS THEREON, FOR USE IN CONVERTER ADAPTED
TO PRODUCE PAD-LIKE CUSHIONING MATERIAL:, AND NETHOD
SPECIFICATION
: This invention~ relate~- in general to a , ` -:~ gear-like stitching assembly adapted for use in a converter mechani~sm~adapted for producing a packaging material or cushioning dunnage, as it is known in ``~
; the~art~,~ and mo~re~ particularly rel~ates to a stitching 10 ~assembly for dunnage producing cQnv~rter mechanism utilizable~for~the~;production of a~strip~of resilient pad-iike~or~pàd-shaped~dunnage produc~ ~rom sheet-like j `-stock~matérial, with the lateral edges of;the sheet-like stock material being rolled inwardly as the stock lS~ material is pulled into the~converter mechanism from a p ~ ~tock~rol~ thèreof,~by~meàn-s~of~ the geas-like s*itcklng~assembly,~ and~;whereln~the latte~ co~prises a~pa~ir~of~coacting gear-l~ike m~e~mbers adapted to tit¢h~together~by~co~ining,~confronting rolled~edge 20~ portion~of~the~ heet-like stock~material to connect the ~Ame ~tQgether~along ;the~central~section of the pad-like~product~in a~direction lengthwise thereoE
Sbe~ t eèh~of~at~least~one~of~ the~`geàr-liko members include~projectioo~ tbèreon~which~are adapted to j 25~ ~ rate~the~stock~matérial àlong~the cèntral~coined ¦ eotion o~f~the~prod wea~pad-Like~product, to ald the ~`~ colned ~ection in~maintaining`the~product in its pad~ ike~form ~ -~
3ACXGROUND~OF~THE~INVENTION
~ ` Dunnage producing conv~rter mechani~m for producing ;resil~ient~pad-like or pàd-shaped cushioning dunn~g~ product in strip-likè form and having ate~l pillow-like~or~plllow-~haped p~rtlons and a central connecting or~joining ~ection, runnlng ~, . .

WO90/1~14 ~ 3 ~ PCT/US9~/02110

-2- ~:
generally lengthwise of the strip o~ dunnage product, --are well ~nown in the art. .``
- U.S. patent No. 4,750,896 dated June 14, . ;
1988 to Anthony J. Komaran~ky, et al and entitled `
5 Method And Mechanism For Producing Cushioning !':,'."
Dunnage Product, discloses a cushioning dunnage -converter or dunnage producing machine of the general type to which the present invention may be applied. .~.
This type of converter mechanism is adapted !~q to take sheets of stock material from a multi-ply stock roll, and pull them into the mechanism while --generally turning or rolling the lateral edges of ;`^``
the sheet-like material inwardly, and then connecting `~
: the rolled, lateral confronting stock material .. =
15 section~ thereof together along the central portion. ~
of thé pad-like or pad-shaped product by coining, ! ~`
and then emitting the strip of cushioning dunnage j `.
: product from the machine, with t~e produced cushioning product comprising relatively resilient, late:rally spaced pillow-like or pillow-shaped sections. or portions, and a generall.y centrally ¦
oriented coined, connecting portion or section, ~: running:generally lengthwise of the strip of :
: : : product. . :
: 25 ~he connecting--mechanism in the type of prior art converter machine previously identified : may be a pair of coacting, generally vertically arranged, gear-like:..members or the like, which coin or deform the adjacent confronting edge~ of the : 30 lateral pillow-like sections of the pad-like .~.
product along the gene~.a-lly central section of . .

,: , -- . , , WO90/13414 2 ~ 31 5 2 ~ P ~/US90/02110

-3- .
the rolled edge strip of stock material, thus :~.
connectlng together the lateral pillow-li~e or ~.
pillow-shaEed sections, and re~ulting in the pad-like ~.,' or pad-shaped dunnage product. ~ .
~5 ~ The~product is adapted to be emitted ~
: through an exit opening in the converter:machine, . 'j, and~a cutter mechanism~is generilly~-;provided for ~ ' 'f severin~ the~st~rip~of cushioning product~into . :
electe.d.lengtb,~for:~use~ in wrapp~ing or packing~
par;ts,~and the like.
In~:U.S~ pate~ne;~:No:.~ 4,7l7,613 dated :
January~5,~1988~to~Gary~W:.~Ott~av:iano ;~and ent~tled~
Mechanism~And~Method~ Producing Cushioning Dunnage~there~:is~dlsc1Osed~a dunnage converter ~ i :
15 ::mechànism~wh~ich is~operable~ to~p~oduce.a~pad~ e cu~hiQning~dunnage~-product of the general type. as~
that:~produced by~the~converter;~mech~ ism of the tter-discussedi~;Komaran~sky,~ét~;~al;~ ~ nt~ ,;;
'There aré~;a~,~nu ber of ath~er;~prior~:~rt .20,~ .paten.t~s~ disolo:~'ing dunnage~producing~echan~sm and ~ , ~unnage:produce oi ~

m~sbo~n~;in::thé~aforediscussed~Ko-~ransky~
25~:.è't::~a'~ Ottavian.o"~pate ~ ~ Somè:'of~t `~`
U.S.. ~patènt~No.~:3,655~ 500~dàted:~April~ l972~to. : .' :G~ R`.~Johnson~and~,~:entieled~A~Re~i:lient~Cushion~ing ' D ~ ~P ~ c ~ U,se~}n~Packa ~ ~:And~Packlng, p~tent~Na;.,.~4,02.6,l98~ Gary~;~W~. Ottaviano . -30, dàeed~May~3l~,~'igi7~and~:entitled~:CushiQning'Dunnage .
I '~Mechan~sm~And~:Transfer~Cart Therefor And,Method, ~

WO90/1~14 2 0 3 1 ~ 2 6 PCT/US90/02110 ~ ..,

-4-both of which disclose resilient pad-like or pad-shaped cushioning dunnage product~ comprising lateral -g¢nerally resilient pil}ow-like or pillow-shaped portions connected along the central portion of the pad lengthwise thereof, together with methods and apparatuses for producing the same.
` ; ~While coin~ing~andlor adhesive means have been utilized in these prior a~rt arrangemènts,~or connecting~or;holding the pillow-~ike~or pillow-shaped `
10~portions~of~the~pad-like or~pad-shaped~product toqether i~n;~pad-l~ike form, to applieants' knowledge, i~
no~one;~prior~to~applicants~ has~provided;a~stitching ~il mechanism~fo~ u~e~in~a~converter~mechanism~ w~ioh includes~perforatlng means~for forming~pèrforations 15~in~the~ ~ duced pad-likè~product~to a:id in the: :r.
- i~ holûing~or securement of~the central connect~ng ;
po~tion~Qf~the~ pad-like~;prodùct,~for~more po~ ~ ~ly~;~aintaining the:~pad-lika~or pad-sh ~ d -form~of~ ;prod~ct,~ and~thus~enhanc~ng use~and~
2~0~p~rformanc~;of the~product.
SUaMAR~OF~
èneion~provides; a ge~r-like st~itching~ as~e~y ~ for~ a~ ~dunnag*~ producing mechanism or convèrt-r,~which~in~a~ddition~to`~connècting;~
together by coining~, con~fronting~roi~led~edge ~
ons~of~s ~ et-like~stoc~ ~ terial,;also cau es ~~~ ~
at ~ n~of~the~s~tock ~ ter~-a~ along t~e ~central coi ~ sèction~o thè~produced; ~ d~likè`or pad-shaped -~
` p ~ t,~to~àid thè~ co~ined~e ~ ion``in ma~ntaining the ` ~~
30~ product ~n~its;~pad-like~for~ A~nove~l méthod of ~ ~~~
producing th coined~and~perforated padTlike or r'' pad-sh p~d~product ~is~al~so~d~sclo~ed. - ~ ~` -WO 90~1 341 ~
2 ~ ~15 2 ~ PCT/US90/02110

-5-Accordingly, an object of the invention is to provide a novel stitching assembly for use in a ;~
dunnage producing mechanism or converter, which is capable of producing an improved pad-like or pad-shaped S dunnage product having both a coined and perforated section running lengthwise of the product, for aiding in maintaining the product during use, in its pad-like or pad-shaped form.
Another object of the invention is to provide a novel dunnage producing or converter mechanism for producing cushioning dunnage for use as packing and/or packaging material, and the like.
Another object of the invention is to provide a mechanism or machine of the latter type ~-15 which includes a gear-like stitching assembly which `~
is operable to both coin and perforate confronting rolled edge portions of the sheet-like stoc~
material durin~ operation of the- mechanism, for a~iding in~ maintaining the produced pad-like product in its pad-like form especially during use of~the product in packaging or packing, such as for instance in wrapping of parts or articles for shipment thereof.
A still further object of the invention is to pro~ide a novel method of perforating a pad-~like cushioning dunnage product along a coined, ~~
lengthwise extending central connecting section thereof to aid such coined connecting section in maintaining the pillow-like or pillow-shaped ~~
lateral ~ections connected, thus aiding in maintaining the pad-like or pad-shaped form of the produced cushioning dunnage product. -..

';
: `

WO90/1~14 ~ 0 3 ~ 5 2 ~ PCT/US90/02110 Other objects and advantages of the ~;
invention will ~e apparent from the following -- description taken in conjunction with the .
accompanying drawing~ wherein: -~
S BRIEF DESCRIPTION OF THE DRAWINGS
FIGU~E 1 is a partially broken, top plan view of a cushioning dunnage producing machine or converter, which embodies the invention;
FIGURE 2 is a partially broken, side 10 elevational view of the mach~ne of FIGURE l; ~-FIGURE 3 is an enlarged, fragmentary, `
perspective illustration of tbe converging member of .
t~e converter and the coacting meshed coining and perforat~ng gear-like means of the stitching assembly for connecting the laterally ar~anged, generally abutting pillow-like portions ~ the dunnage product : .
to~et~er,~ and illustrating the passage of the rolled edge stoc~ material into the:stitching asse~bly; I ;
FIGURE 4 is an enlarged fragmentary, perspective view of the meshed connecting gear-like members of the stitching aRsembly disposed adjacent , ~
the exit end of the converging me~ber of the ! -;. ~ .. .
converter mechanism, and illustrating projections : on the teeth of the gear-like members of the '```!'`
2.5 ~titcbing assembly; _ `-- FIGURE S is an enlarged, partially diagrammatic, side elevational view of the idler - gear-~ike member of the stitching assembly;
- :- ~ ~ P}GURE 6 is a partial sectional view ;~
~aken generally along line 6-6 of FIGURE 5;
FIGURE 7 is an enlarged, partially -`
-- - diagra~atic, side elevational view of the driven : geAr-like member of the stitching assembly~

.. ..
.

WO 90/13414 2 ~ 3 ~ 5 2 ~ PCI/US90/02110 FIGURE 8 is a partial sectional view taken generally along lin~ 8-8 of FIGURE 7;
-= FIGURE 9 is an enlarged diagrammatic, perspective plan view of a strip of the produced pad-like or pad-shaped cushioning dunnage product; and FIGURE 10 is an enlarged, generally fragmentary, diagrammatic illustration taken generally alonq the ~:~
plane of cross sectional line 10-10 of FIGU~E 9.
DESCR~PTION OF PREFERRED EMBODIMENT
10Referring now again to the drawings, there is illustrated a dunnage producing machine 10, or converter as it ifi known in the ar~, wh~ch, in the embodiment illustrated, utilizes a multi-p~y stock roll 12 of sheet-like stock material, such as, for instance, 30 pound kraft paper sheet. In the embodiment of stock roll illu~trated in, for ~ :;
instance, FIGURES 1 and 2, the plies of the stock roll are preferably of equal width and in this embodi~ent comprise three plies disposed in roll - :20 form, for expeditious and compact installation on the dunnage producing machine or converter.
Stock roll 12, in the embodiment I `
illustrated, comprises a hollow core 14 of generally `
cyl~ndrical configuration on which the three : ~ 25 super-imposed webs or sheets of stock material are---- wound. The stock roll is adapted to be mounted on :
a supporting rod 16 extending preferably relatively :-ioosely through the core 14, for rotation of the .
- -stoc~ roll 12 relative to the supporting frame ., structure 18 as the stock is d~awn from the roll . ~ into the dunnage machine.
,- ., '':
,. , , - ,:
.,, - .

.. I ,.

WO90/13414 2 0 ~ 1 S 2 PCT/US90/02110 ~:
~-8- `
Reference may be had to aforementioned U.S. patent No.4 750 896 which is incorporated : herein by reference for a more detailed explanation of the mounting af the stock roll on the converter. ,!;.~.
It will also be understood that the ~tock roll:
~: could be:mounted on a separate stand or cart and the plies therein fed into the converter in a ~manner~known in the art (e.g. U.S. patent No.
41 650 456 in th:e name~of Steven E. Armington and i~ssued-March 17 19:87).
Machine:lO in the~embodiment.illus:trated co~prises~an~enclo~ed or sheathed:support framework 20 including~ieg portions~20a which may ihclude I .^
: : me~ns~ t~not;~sbown~::associated therewith for leveling ~.
lS~ the~upport~fra~ework with re~pect to the ~upporting. ;~
- ~urf~ce S.
Pramework.~20~supports a~ l~ngitudinally J~ ~convèrging~c~hute-like~e~ber~22 (FIGURES~l and~21 wh~ch::chute~or~converging~m~e~ber~forms~ a guld~and ~: 20:: ~uppo~t~for~the~:webs~;or~pl:ies;~of stock ma:ter~al 8 t bey~are~drawn~of~f~th~ stoc~ roll~l2:and:~are .
p~asea tow~ard.:~connecting~or ~tltchinq~echani-m se~tion~-24~of~the~dunnage~produ~ing mach~ine.
:A~:three~dimensio~al stock formin~..`frame 2~5 26:whi¢h~ in~thè~e~bodiment~ llustrat-d~compri~eJ a ~
tubular:~frame~ dyl~ tion~of~gen * ally trizmgDl~ar-h~pe~in~plan~ F~GURE~ is~ upported in~the~ chute `
and~projects~rearwardly~of~the en~ry~end~22a-:of _.
the~chute~or::~;converg~ng~.~emher ~2.: :Stock form~n~ - --mechanism 26~at it~forward no-- end 2~6a i8 - - - '4~;`
.~:
preferabiy disposed relatlvely clo~e to the ..
: underlyIng bottom wall of the chute 22 adjacen~
th :-xit -nd 22b ther-of and a~ ustrated in ~.

::
- :~
, : I ..

WO90/13414 ,~ 31 5 2 ~ PCT/US90/02110 ~

_g ~
FIGURES l and 2. The webs of stock material are adapted to move or slide between the nose end 26a and the chute exit end 22b during movement of the stock material from the stock roll 12 to the connectlng S or stitching section 24, which pulls the stock material through the machine ! and causes discharge of the produced resilient dunna~e pad product P through -~;
exit opening 28 in the machine frame 20.
Connecting or stitching section 24 of the converter includes, in the embodiment illustrated, stitching assembly 30 comprising rotatab}e, generally loosely meshed gear-like members 30a, 30b, wh~ch are~adapted~to Ucoin~ abutting lateral p~l~ow-like~or~pillow shaped portions of the lS produced~pà~-like product~, as the rotating;gear~ e `~members move the product through the converter and `;
out exit~opening 28. An~electric motor and speed i reducer~mecha~nism 32, 32a~;~may be utilized~to drive I i!',.~.
one of~the~gear-like stitching ~embers ~i.e.- member 30b)~ wh~ch~bèc~ause~of~its generally~me~shed relotion w1th the~;othe`r of~ aid~members (i.e. we~ber 30a) ¦
ikewise~causes;rotation of the la~ter. Reference may~e`~had to aforemention-d ~ tent No. 4,750,896 for a~ re;~detailed~disclosure;of a-converter mechanism~,~1ncludinq pus~her or forming frame ~ ~ me~hanism~26 of the~general type shown ~n ~ i ~`
-~ ;FIGURES~l~ and~2,~together with the operation - ! ,`~`
thereof.~ i~i As~the~sheet-~likè s~tock ma~e~ial ~~s ~t pulled from the stock roll ~hrough the c~ute 22 by connecting or ~titching mechanism 24, the side edges of the stock webs are rolled-inwardly into ` '; !
' ', ' _ ., ~.~

,, . .

`'~'~
~'.'.
~ ~ ~ `~'`
:: ~ ~
~:
j ' ,'.'~

WO90/1~14 ~ 0 31 5 2 & PCT/US90/02110 . ~

--10-- ~.
generally spiral form and are urged inwardly toward one another so that the inwardly rolled edges form ,~.
resilient pillow-like or pillow-shaped portions 34 .~-' ~FIGURES 1, 2 an~ 9) of stock material disposed in 5 generally abutting relationship as they merge l.
from the exit ènd of the chute-like member 22 and .. ;
pass into the rotatable connecting or stitching section 24 of the converter mechanism where such inwardly rolled:edges of the stock material are .~'' 10 ~adapted.to be ~oined or stitched together .~ lengt:hwi e of the produced dunnage product, by .. ,,`
the~rotating gear-like members 30a, 30b thus : re~sulring in. a generally oentral coined sectio~
~:3:6:on~:the product e`xtending lengthwise of the pad-like product, and~stitching together :~FIGURES
,l and,9) the compressed, overlapped abutting ! !' j~
coin:ed~edges 36a and 36b (FIGURE 9) of the:
forméd~pillow-lik:e~portions;of the. pad~ e or :p~d-sh~ped~product. The latter edges 36a, 36b , !~
20`~are~generally~disposed Ln generally random over-lapped:~relation as~ illustratèd, along the central compre~sed~co~ined connecting:section 36 of the produced~pad-like:product. , ;~
he: laterally arranged pillow-like or `~
25~ pillow-ahaped portions 34 of~the pad-like cushioning : product~possess~considerable resiliency, e~ch being ..
: : of a substantial:ly greater thickness than the~
;compressed~¢entral aoined~portion 36. The coining o;f~the~product:,by the~gear-}ike members 30a, 30b produces flat~or valley sections 38 with :
~! intermediate rise sections 39, with the rise ~ ~ sections projecting outwardly from the level of ."
:~t~
:, wo 90J13414 2 0 3 1 5 2 ~ Pcr/us9o/o2l 10 the associated flat or valley sections, and as clearly shown for instance in FIGVRE 10. '.
Referring now in pa~ticular to FIGURES 1 and .' ::2, there is provided at the forward end of the e~bodiment ~~
~ 5 of converter machine illustrated, a separati:ng mechanism .:
:40 wbich is adapted to receive ~he sheet-like seock .. `
material from the stocX roll 12 and to separate the - multi-plIes: of the:roll into ~ndividual pl~es or webs :
of~stock:mater~ial prior to their passing beneath the 10 ~:fo ~1n~ fr~me~26 and~ into: the converging chute-like ' membér~22~, thus~aiding in~maintaining the resiliency ' .'.
of~the~producet~dunnsge~product P~ ;Sep~arating means j 1.
40 i~n~ the:embodiment'illustrated, compri~es a j i.
:plurality of:~vertic~ally~spaced,~ general~y lS~horlzontalIy~oriented cyli'ndrical bar~ e elements l ~' 40a~, ~40b and 40c about wh~ch is~adapted to pass the especti~ve:web a, b and c of the stock:material 1-from:th~roèatable~stock~roll,~pr~or to passage ¦
the~r.~f~und rneath~;the~:forming~frame 26-:~and into 20 ~Gonverging :chute~ember:~22:- .
As~can~be~best~seen~in FIGURE~2, the~
transYerse~bàr-like~member~4`0c i:s- preferab~y :o'~a~;~a'terially greater`~thicknes:s;~or~d~ameter~as j~
co~p~red:to:~those~of~the:~uppe~r:bar-like~membe:rs ~ .
25 ~Oa~and~40b~ wleh~ember~;4~0c;~preSera~ly being ' ~
rotatably;mounted~on~thè:~upper;~a~ 8b o;f'~he :' re~p~ctlYe:~support~bracket 18~.~ Me~bers~4~0a, 40b ~.
and~'40c:~re;:~all prèferàbly:rotatable: with re~ ~ ct - "~
: to ~heir~moùnting:~t~ucture. ~ ~ : :~
30: ~ The~ rrangement~of~the s;tock material : ~ :: w-bs a, b and o wit~ respect to the separating : :bar- 40a, 40b and 40c are preferably a~ shown'ln !~
:`:

~ ~ A ,~`
.`

, : ~ ''`:

WO90/13414 2~3~ Pcr/usgn/o2ll0 -12- .
FIG~RE 2. Webs b and c both may engage ro~ler~40~ `
whîle web a passes over rotatable bar 40blas show,n in ~
FIGURE 2. The rotatable mounting of elements 40a ~40b and 40c aids in preventing tearing of the\sheet or \
web stock material in its passage through ~e machine Disposed outwardly from separating \ `~
mechanism 40 and also supported on upper arm 18b-is - preferably a further bar member 42 which in the .~.
embodiment illustrated is a rotatable roller lO having a cylindrical exterior surface, wit~ the .
ends of roller 42 being rotatably mounted directly ~ ~.
on ~he spaced.upper arms 18b of U-brackets 18.~ `.5''!
Roller member 42 provides a non-varyin~
point of entry of the plies of sheet-like stock ! ~`~
material from the stock roll 12, as they (the plies) are pulied into the dunnage producing mechanism toward the separating means 40, and irrespecti~e ,.`.
of the diameter of the stock.roll. Thus in the j .:
event of~utilizing a larger diameter roll, or as I ~
20 the stoc~ ro}l is used up during operation of the ~ .
converter mechanism, the point of entry of the material toward the separating means remains . cons~ant, thus facilitating a more uniform :~ production of dunnage pad product from the ~echanism.
25 Reference may be had to--~aforementioned U.S. patent :~
~o. 4,750,896 for a more-~etai~ed-description of :
: separating mechanism 40 and associated common .
entry point member 42. . . . . _ After passing through the exit opening ~8 :
- -of the converter, the continuously formed pad-like product.P is adapted to be severed by a cutter mechanism 44 mounted on the convcrter machine .

!~ `
. ::

":``

WO90/1~14 2 0 3 ~ ~ 2 6 PCT/US90/02110 ,.;
-l3- (.~'' generalLy ad~ac~nt the exit.opening 28, to cut the :, strip of produced dunnage product into desired ,, lengths.
Referring now in particular to FIGURES 3 '.' and 4, the generally loosely mea~ed, substantially ,,,,~
vertically arranged gear~ e members 30a, 30b are 1',.'.
:rotatably mounted as by~means of a respective,shaft `
~: 46:,~ 46a. ~Shaf;t: 46 of the upper idler gear-like ,,~
member~30a is preferably a~ranged with the ends~of .-.
:10 the~ sha~t being mounted~in~:slotted bracke:t frames 48 (F~GURE~3~ and wit~ both:of~the~ends of the~shaf~t 1, being~spring~;loaded~as~at~50:, for:ùrginq shaf;t:4,6 ~, and asæociated;géar-like;~member 30a~downwa~dly toward:~the~:under~lying~gear~-like member 30b. It t~
15; will~be~seen~ther~fore~ that the top member:~30a which is rotatable~relative to its supporting shaft '1~`5 46~generally~ fIoats~ due~to~supporting slotted 1 .
brackét.~ tructure~4,8~with~member ~3:0a and::associated s:~aft 46~'~bèing~`movable~vertically:relative to the `
20~ r ~ ng`~member 36b~ to thus~provide for `
~c~v~ing~of ~the~ ~space:;between the teèth of~thé geàr-like me ~ ers:in;the event of varying ~;amounes;or thickneJses~of~thè:~sheet-lLke stock ater~al:~attèmpting~to~:pass~ther`ebetween~:duriDg.the 25:~' connecting~o,~;;sti~ching:~operation.: `Such arrang'ement ,' ~, ds:~'in~Rreventing tear.ing~;of~t~ ~st ck ~ terial due to:~too~bard~meshing~,between the~:gear-like;members : of tbe:~ stitchi,ng,: ~sse~bly~ 3Q~ As c~n: be~est seen ~' in PIGURE~:~4,,,~;thel ,undèr1ying ~driven gèar-like member '~::30:: projécts:~upwardly~~through~à slot':or opening 5 2 ~ in ~ generally~'~hor~zontal;support plate 54, which extends :.:
: : ~` between the,~u~e member 22 and the product eXit =--,;
. .
~- : ..

, .``

woso/1~14 ~ O PCT/~S90/02110 opening 28 of the dunnage producing machine.
Shaft 46 is preferably provided with roller ~;
sleeves 56 tFIGURES 3 and 4) on both sides of the gear 30a so that as the crumpled rolled edge stock material `~
S emerges from the exit end 22b of the chute member 22, ~
it passes beneath the shaft 46 and associated roller ;~i sleeves 56 which are rotatable relative to the shaft, and thus aid in preventing tearing of the pad-like product as the connecting or stitching assembly 30 coins the generally central portion of the strip of product, and connects the lateral pillow-like sections 34 thereof together, as illustrated for instance in FIGURE 9, prior to emergence of the finished product from the machine. -~
The under~ying connector gear-like member 30b is keyed or fixed to its shaft 46a, the ~-latter being rotatably mounted at its ends in bearing structure 58, and may include a sproc~et 60 secured ~djacent one end of shaft 46a, and which sprocket 60 ~`
20 ~ in turn is connected as by an endless chain or bel~ ~-~
to aforementioned geared speed reducer 32a. ~-~
FIGURES 5-8 illustrate enlarged detail views of gear-like members 30a, 30b, wherein such members are basically spur gears with the teeth 64 thereof embodying the 14~ Deg. Involute System. In ~ ~
accordance with the invention however, the teeth ~ ~
have ~een cut or formed to provide projections 66, 66a thereon, with such projections being spaced - - - -~--- -laterally of one another in a direction transver~e -~ --of the tooth (FIGURES 6 and 8). The cen~ral projection 66a in each row of projections is preferably of a greater width as compared to the -. _.,~,,i- `, : -WO90/13414 2 ~ 3 ~ 5 2 6 PCT/US90/02110 --15-- ~,,,:, width of each of the other projections 66 in the , respective row of pro~ections, and as illustrated. .
The driven gear-like member 30b, in_the embodiment illustrated, has threaded open~ nqs 68 formed therein for receivinq threaded 6et scr-ws : (not~hown) for fix~ng or locking the~member 30b to : its~ :associated sha~t 46a. ~The idler gear 30a~ i9. ' :rotatable~ ~with respect~ to its associated~ shaft~ 46, ~ and~may~ be~ provided ~w~ith~a sleeve~bèaring 70 :for :~: 10~ faci:l~itating:~ rotat:ion;of ~gear 30a with respect to :shaft 46:.:
Durinq~rotation~of~ehe gears~as~a~fore~
described~in'~connection~with operation of thé I '~
converter~:mechanism,~the~projections 6:6:, 66a ~on ~:;15 ~tbe~t-eth~,simùltaneoùs1y~with~ the coining~ o~`the `
central ~ection:36 of;~the produced product, pierce or perforate~the~underlyinq~co~ressed~stock~material to ~fo~ s ~ éd~open ~ d:i~po-ad trànsve~se of the ~ ,:
:cen~t~al~connecti~ng~s~ectlon~36~o~f~the~p~oduct,~:and ~, 2~0~ 'extending~i~n~a~ di:rection~lengthwise~of` the ~ - i~
product,~to~:a~d~the:`coined~portion~in~maint~in~ing ,~
the~product~in:~ t~;pad-like:~or pad-shaped`,form,~thus , ,~;
itating~ the use~of~the~p ~duct:~as~packing;~or , , ~ material.~ }n~;oth-r~;words,~the~pe:rforations '2~S~ 72,,`~IGURE9 9~and~;10~ stake~thè~compre~s-d stock ~ '~' ;, mater~al;~;togeth,er along~¦thè~central:connectlng ' ' section~3;G~of~th-~produat`,~:and~:~a~id~the~ coined~
:portion~n~preven~ng~opening:~up or~`sep~r~atio~ of~
t:he~,connèct~ng~section~of,;tne~prod~ct.;~ ~ ~ ~~ '~
30 ~ A:pre~ssure~o~:approximately lO~ p.s.i. is -preferred as~ap`plled by each spring unlt 50 to sbaft ,, : 46~,~to thu~resist~ovement~:of-the idler member Oa- '~

" ~ .

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WO90/13414 2~3~ 6- PCT/US90/02110 away from the driven member during the stitching ~-~
operation by the stitching assembly 30. ~owever, _means 74 is preferably provided coacting with each spring unit 50, for varying the pressure applied to !"'"' the shaft by the respective spring unit. If for instance heavier webs or sheets of stock material are utilized for the stock material, then the adjusting means 74 can be turned or actuated to increase the p.s.i. pressure for obtaining satisfactory coining and perforation or piercing of the central connecting section of the product.
However, for the usual tri-ply, 30 pound kraft paper stock roll utilized in connection with the converter to form the produced product, a set-up or pre-appl~ed I ;
pressure of approximately lO p.s.i. for each spring unit ~0 is preferred.
From the foregoing discussion and accompanying drawings it will be seen that the j ~inven~tion provides a novel stitching assembly useable ! :-20 in different types of cushioning dunnage producing ', ~
- machines~or converters which includes means for -perforating or piercing the stock material along the central connecting section of the produced pad-like -~
cushionin~ product, for aiding the coined sectlon `
of the product in maintaining the product in its pad-~ike form. The invention also provides a novel converter mechanism embodying a stitching asse~bly ~;
of -t~e~~atter type, as well as a novel method of produc~ng pad-like cushioning dunnage ~naterial from wéb-like or sheet-like stock material.
~ he terms and expressions which have been use~ are-used as terms of description and not of WO9~/1~14 2 ~ 3 I S 2 ~ PCT/US90/02110 ~

limitation, and there is not intention in the use of such terms and expressions of excluding any ~
- equivalents of any of the features shown or , .-described, or portions thereof, and it is s 5 recognized that various modifications are possible :.
within the scope of the invention claimed.
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Claims

- 18 -

1. A gear-like stitching assembly adapted for use in a converter mechanism utilizable for the production of pad-like cushioning dunnage product from sheet-like stock material disposed in stock roll form, the converter being operable to cause inward rolling of the lateral edges of the sheet-like stock material into generally rolled form prior to being formed into the pad-like product, said stitching assembly being operable to receive generally abutting rolled edge portions of the sheet-like stock material, and to connect the same together along the generally central section of the produced pad-like product in a direction lengthwise thereof, said stitching assembly comprising a pair or rotatable, gear-like members adapted to be disposed in meshed condition and to stitch confronting rolled edge portions of the sheet-like stock material together by coining as the latter rolled edge portions pass between said members, and characterized by the teeth of at least one of said members having projections thereon for perforating the stock material along the central coined section of the produced pad-like cushioning dunnage product, to aid the coined section in maintaining the product in its pad-like form.

2. A stitching assembly in accordance with claim 1 including means providing for movably mounting one of said gear-like members with respect to the other of said members for providing for to and from movement of the gear-like members relative to one another during the stitching operation.

3. A stitching assembly in accordance with claim 1 wherein said projections comprise a plurality of spaced projections on each of the teeth of said one member oriented with respect to one another in a direction transverse of the respective tooth of said one member.

4. A stitching assembly in accordance with claim 3 wherein each of said spaced projections is of a greater dimension in a direction lengthwise of the one member as compared to the direction transverse of said one member.

5. A stitching assembly in accordance with claim 3 wherein said spaced projections on each tooth comprise one projection disposed generally coplanar with the vertical longitudinal center planes of the one member and other projections being spaced }atonally of said plane and of said one projection on opposite sides thereof.

6. A stitching assembly in accordance with claim wherein said members are spur gears, with the teeth of each said member having said projections thereon.

7. A stitching assembly in accordance with claim 1 including a mounting shaft for each said members.

8. A stitching assembly in accordance with claim 7 wherein the shaft for one of said members is non-movably connected thereto while said shaft for the other of said members is rotatable relative to said other member, and thus the latter is on idler.

9. A stitching assembly in accordance with claim 6 wherein the gear teeth embody the 14? Deg.
Involute System and each said spur gear embodies eleven teeth.

10. A spur gear of the type adapted for use in an assembly of the nature of claim 1 and including said projections on at least some of the teeth thereof.

11. A spur gear in accordance with claim 10 including a transverse axial opening therethrough for mounting said spur gear on a shaft.

12. In a converter mechanism for producing pad-like cushioning dunnage product from sheet-like stock material comprising a support, means on said support for causing inward rolling of the lateral edges of the stock material into generally rolled form, and gear-like stitching means on the support adapted to receive confronting rolled edge portions of the sheet-like stock material and to connect the same along the generally central section of the produced pad-like product in a direction lengthwise thereof, said stitching means comprising a pair of spaced meshed, rotatable toothed gear-like members adapted to stitch confronting rolled edge portions of the sheet-like stock material together by coining as such rolled edge portions pass between said members, and wherein the teeth of at least one of said members have projections thereon for perforating the stock material along the central coined section of the produced cushioning dunnage product, to aid the coined section in maintaining the product in its pad-like form.

13. A converter mechanism in accordance with claim 12 wherein said stitching means includes means providing for movably mounting one of said members relative to the other of said members in directions toward and away from one another, thus providing for relative generally linear movement of said members relative to one another.

14. A converter mechanism in accordance with claim 13 wherein said stitching means includes spring means coacting with the last mentioned said one member for resisting said linear movement in at least one of said directions.

15. In a method of producing cushioning dunnage product in pad-like form from sheet-like stock material and wherein the product comprises lateral pillow-like portions connected by a central section extending lengthwise of the product, comprising taking at least one web of sheet-like stock material and moving it longitudinally while rolling the lateral edges of the web inwardly into generally spiral form and causing such inwardly rolled edge portions to be disposed into generally abutting condition, and then connecting the rolled edge portions together by coining thereof along the juncture thereof and transversely of the pad-like product lengthwise thereof to form the central connecting section of the product, and including the step of perforating the stock material along the central connecting section to aid in connecting the lateral rolled edge pillow-like portions together.

16. A method in accordance with claim 15 wherein said coining and said perforating are done substantially simultaneously.

17. A method in accordance with claim 15 wherein said coining is accomplished by providing a pair of meshed gear-like members through which said rolled edge portions are passed to connect said rolled edge portions together by said coining, and providing projections on the teeth of said gear-like members to cause said perforation of the stock material along said central coined section during passage of said abutting rolled edge portions through said gear-like members.

18. A method in accordance with claim 15 including providing for to and from movement of the gear-like members relative to one another during the connecting operation to aid in preventing tearing of the stock material, while applying a pressure of approximately 10 p.s.i. to the movable gear-like member on each side thereof to resist its movement away from the other gear-like member.

19. A method in accordance with claim 15 including the step of providing a predetermined width multiply roll of the sheet-like stock material and mounting it for rotation about its axis of curvature prior to said moving of the sheet-like stock material longitudinally.

20. A method in accordance with claim 19 including providing three plies of the sheet-like stock material in said roll form.