System for producing dunnage

Abstract

The dunnage conversion machine includes a drive mechanism configured to deform raw material into dunnage. The drive mechanism may include a roller having an outer surface of a first shape, and another roller having an outer surface of a second shape different from the first shape. The dunnage conversion machine may also include a cutting mechanism including an anvil having a curved surface and a cutting portion, where the anvil and the cutting portion are configured to cut the dunnage. The dunnage conversion machine may also include an inlet chute configured to feed raw material to the dunnage conversion machine. The inlet chute may include a protrusion located within an interior passage of the inlet chute configured to restrict downward movement of larger objects, such as fingers and hands of an operator, along the interior passage.

Description

Technical Field

[0001] The present disclosure relates to systems for converting paper stock and other materials into dunnage for use as packaging material. Background Art

[0002] Paper protective packaging or padding is produced by crumpling or otherwise deforming a paper raw material. More specifically, paper padding is produced by passing a substantially continuous strip of paper through a padding converter. The continuous strip of paper can be provided, for example, by a roll of paper or a stack of folded paper. Pad conversion machines convert raw material into a lower density padding material by, for example, passing the raw material between opposing rollers. The rollers grasp and pull the raw material in the roll or stack of paper, deforming the raw material as it passes between the rollers. The resulting padding can be cut to a desired length to effectively fill the void space within a container containing the product. Pads can be produced as needed for an individual or machine performing a packaging operation.

[0003] The ability to provide a smooth, continuous feed of paper stock from a stack or roll is critical to the proper, efficient operation of a dunnage converting machine. If a jam or other interruption occurs in the flow of paper stock to a dunnage converting machine, the machine will not be able to produce dunnage at the required rate, which can cause delays in packaging and shipping operations that rely on the dunnage supply. Frequent jams can also cause damage to the dunnage converting machine and increase maintenance costs.

[0004] The ability to cut dunnage cleanly and repeatedly is also important to the proper and efficient operation of a dunnage converter. For example, cutting blades need to be replaced regularly to ensure that the edges are sharp enough to cut newly formed dunnage into individual pieces. Therefore, being able to quickly and safely change a dunnage converter's cutting blades is a desirable feature.

[0005] In addition, the final shape of the pad is also determined by the rollers that crepe or deform the paper stock. It is desirable that the rollers deform the paper stock to substantially increase the total volume occupied by the converted paper stock (i.e., the pad) so that the pad can achieve its intended purpose of fill volume and cushioning. Summary of the invention

[0006] In one aspect of the disclosed technology, a dunnage conversion machine includes a drive mechanism configured to deform raw material into dunnage and a cutting mechanism. The cutting mechanism includes an anvil having a surface consisting of a curve and a cutting portion. The anvil and the cutting portion are configured to cut dunnage.

[0007] In another aspect of the disclosed technology, the drive mechanism includes one or more rollers.

[0008] In another aspect of the disclosed technology, the cutting portion includes a blade.

[0009] In another aspect of the disclosed technology, the surface of the anvil comprised of the curve is a convex surface.

[0010] In another aspect of the disclosed technology, at least one of the anvil and the cutting portion is configured to move relative to the other of the anvil and the cutting portion to cut the underlayment.

[0011] In another aspect of the disclosed technology, the anvil is stationary and the cutting portion is configured to move relative to the anvil to cut the underlayment.

[0012] In another aspect of the disclosed technology, the anvil is configured such that as the cutting portion or anvil moves to cut the underlay material, the underlay material is urged about the convex surface.

[0013] In another aspect of the disclosed technology, an opening is defined in the anvil and is configured to allow padding material to pass through the anvil, and the opening is at least partially defined by a convex surface.

[0014] In another aspect of the disclosed technology, the anvil further comprises a first side surface and a second side surface. The opening is further defined by the first and second side surfaces, and the anvil is further configured such that when the cutting portion of the anvil moves to cut the pad material, the pad material is pushed toward the first and second side surfaces.

[0015] In another aspect of the disclosed technology, the curved surface of the anvil includes a sharp edge configured to cut the underlayment.

[0016] In another aspect of the disclosed technology, a blade includes a tip configured to cut underlayment.

[0017] In another aspect of the disclosed technology, the blade includes a beveled leading edge.

[0018] In another aspect of the disclosed technology, a blade includes a leading edge having a convex shape.

[0019] In another aspect of the disclosed technology, the leading edge is configured to push the pad material to one side of the cutting portion when the blade cuts the pad material.

[0020] In another aspect of the disclosed technology, the leading edge is substantially straight.

[0021] In another aspect of the disclosed technology, the anvil includes a tip. The tip of the anvil and the tip of the cutting portion are configured to approach each other when the anvil and / or the cutting mechanism moves relative to the other of the anvil and the cutting mechanism.

[0022] In another aspect of the disclosed technology, a dunnage conversion machine includes: a drive mechanism configured to deform raw material into dunnage; and a cutting mechanism having a shuttle and a cutting portion. The cutting portion is configured to cooperate with the shuttle so that movement of the shuttle drives the cutting portion to cut the dunnage.

[0023] In another aspect of the disclosed technology, the drive mechanism includes one or more rollers.

[0024] In another aspect of the disclosed technology, the cutting portion includes a blade.

[0025] In another aspect of the disclosed technology, the shuttle includes a protrusion having a base and wings extending laterally from the base, and the cutting portion is configured to receive the protrusion.

[0026] In another aspect of the disclosed technology, the dunnage is fed to the cutting mechanism in a first direction, and the shuttle and cutting portion are configured to move relative to the dunnage in a second direction substantially perpendicular to the first direction.

[0027] In another aspect of the disclosed technology, one of the shuttle and the cutting portion includes a protrusion, and the other of the shuttle and the cutting portion is configured to receive the protrusion.

[0028] In another aspect of the disclosed technology, the protrusion is configured to engage the other of the shuttle and the cutting portion, and the engagement of the protrusion with the other of the shuttle and the cutting portion couples the shuttle to the cutting portion for movement in the second direction.

[0029] In another aspect of the disclosed technology, the other of the shuttle and the cutting portion has one or more openings formed therein, and the one or more openings are configured to receive the protrusions.

[0030] In another aspect of the disclosed technology, the shape and size of the one or more openings are substantially the same as the corresponding shape and size of the protrusions.

[0031] In another aspect of the disclosed technology, the protrusion is substantially T-shaped.

[0032] In another aspect of the disclosed technology, a protrusion includes a base and a wing extending laterally from the base.

[0033] In another aspect of the disclosed technology, movement of the cutting portion relative to the shuttle in a first direction is limited by the base, and movement of the cutting portion relative to the shuttle in a second direction perpendicular to the first direction is limited by the wing.

[0034] In another aspect of the disclosed technology, the shuttle is configured to move the cutting portion along a cutting plane to cut the underlayment, and the protrusion is located in a plane substantially parallel to the cutting plane.

[0035] In another aspect of the disclosed technology, the shuttle is configured to move the cutting portion along a cutting plane to cut the underlayment, and the protrusion is located in a plane substantially parallel to the cutting plane.

[0036] In another aspect of the disclosed technology, the protrusion is integrally formed with the remainder of the shuttle.

[0037] In another aspect of the disclosed technology, a dunnage conversion machine includes: a drive mechanism configured to deform raw material into dunnage; and a cutting mechanism. The cutting mechanism includes: a cutting portion; a shuttle configured to move the cutting portion along a plane to cut the dunnage; and a motor assembly including a rotatable crank configured to be coupled to the shuttle such that rotation of the crank moves the shuttle along the plane. When the crank is in a first angular position relative to the shuttle, the shuttle is configured to disengage from the crank by moving the shuttle along the plane.

[0038] In another aspect of the disclosed technology, the drive mechanism includes one or more rollers.

[0039] In another aspect of the disclosed technology, the cutting portion includes a blade.

[0040] In another aspect of the disclosed technology, the shuttle is configured to move the cutting portion along the plane to cut the blanket when the crank moves from a first angular position to a second angular position.

[0041] In another aspect of the disclosed technology, the second angular position is offset from the first angular position by approximately 180 degrees.

[0042] In another aspect of the disclosed technology, the shuttle is configured to move the cutting portion along a plane in a first direction, the shuttle defines a track having a longitudinal axis oriented along a second direction substantially perpendicular to the first direction, and the crank is configured to engage the shuttle via the track.

[0043] In another aspect of the disclosed technology, the shuttle further defines an opening adjacent the track, the crank includes a protrusion, the track is configured to receive the protrusion, and the shuttle is further configured to disengage from the crank when the protrusion is aligned with the opening.

[0044] In another aspect of the disclosed technology, the shuttle is further configured to disengage from the crank only when the protrusion is aligned with the opening.

[0045] In another aspect of the disclosed technology, the shuttle is further configured such that the protrusion is aligned with the opening only when the crank is in the first or second angular position.

[0046] In another aspect of the disclosed technology, the shuttle is configured to move the cutting portion in a first direction along a plane, and the shuttle is further configured to disengage from the crank by moving the shuttle in a direction opposite to the first direction along the plane.

[0047] In another aspect of the disclosed technology, a dunnage conversion machine includes: a drive mechanism configured to deform raw material into dunnage; and a cutting mechanism. The cutting mechanism includes an anvil, a cutting portion, and a magnet mounted on one of the cutting portion and the anvil, the magnet being configured to magnetically and slidably couple the cutting portion and the anvil.

[0048] In another aspect of the disclosed technology, the drive mechanism includes one or more rollers.

[0049] In another aspect of the disclosed technology, the cutting portion includes a blade.

[0050] In another aspect of the disclosed technology, the cutting portion or anvil defines a recess configured to receive a magnet.

[0051] In another aspect of the disclosed technology, the cutting portion further includes a first edge, and the magnet is mounted on the cutting portion adjacent to the first edge.

[0052] In another aspect of the disclosed technology, the magnet is a first magnet, and the cutting portion further includes a second magnet and a second edge, and the second magnet is mounted near the second edge.

[0053] In another aspect of the disclosed technology, the first edge defines a first side of the cutting portion and the second edge defines a second side of the cutting portion.

[0054] In another aspect of the disclosed technology, a system for producing dunnage includes: a dunnage conversion machine configured to transform raw material into dunnage; and a feed port including an inlet chute configured to feed a high-density material line to the dunnage conversion machine. The inlet chute includes a first wall having a first surface and a second wall having a second surface. The first surface and the second surface define an internal passage.

[0055] The internal channel is configured to form a portion of a material path for raw material along which the high density material is fed to the padding conversion machine, the second surface is configured to form a protrusion extending toward the first surface, and the protrusion and the opposing portion of the first surface define a restriction within the internal channel.

[0056]

[0011] In another aspect of the disclosed technology, a dunnage conversion machine includes one or more rollers.

[0057] In another aspect of the disclosed technology, the restriction is configured to allow high-density materials to move through the restriction, and the restriction is also configured to prevent objects having a size exceeding a predetermined value from moving through the restriction.

[0058] In another aspect of the disclosed technology, the restriction is configured to allow the high density material to move past the restriction, and the restriction is also configured to prevent the user's fingers and / or hands from moving past the restriction.

[0059] In another aspect of the disclosed technology, the first surface is substantially planar.

[0060] In another aspect of the disclosed technology, the first surface is planar.

[0061] In another aspect of the disclosed technology, the first surface has a larger radius.

[0062] In another aspect of the disclosed technology, the first surface has a radius of curvature greater than about ten feet.

[0063] In another aspect of the disclosed technology, the first surface is substantially horizontal.

[0064] In another aspect of the disclosed technology, the first surface is substantially planar along the entire length of the first wall.

[0065] In another aspect of the disclosed technology, the first wall is a bottom wall of the inlet chute and the second wall is a top wall of the inlet chute.

[0066] In another aspect of the disclosed technology, the inlet chute includes an inlet end and an outlet end, and the restriction is located closer to the inlet end than to the outlet end.

[0067] In another aspect of the disclosed technology, the inlet chute has a first width at the second location, the inlet chute has a second width at the outlet end, and the first width is greater than the second width.

[0068] In another aspect of the disclosed technology, the second wall is inclined at a first angle relative to the material path upstream of the second location, the second wall is inclined at a second angle relative to the material path downstream of the second location, and the first angle is steeper than the second angle.

[0069] In another aspect of the disclosed technology, a system for producing dunnage includes a dunnage conversion machine configured to transform raw material into dunnage and a feed port. The feed port includes an inlet chute configured to supply raw material to the dunnage conversion machine, and a guide configured to guide the raw material to the inlet chute. The guide defines an orifice for receiving the raw material.

[0070]

[0011] In another aspect of the disclosed technology, a dunnage conversion machine includes one or more rollers.

[0071] In another aspect of the disclosed technology, a guide includes a first guide surface configured to guide raw material in a first configuration to an inlet chute and to an orifice.

[0072] In another aspect of the disclosed technology, the first guide surface is a leading edge of the guide.

[0073] In another aspect of the disclosed technology, the first guide surface has a substantially arcuate shape.

[0074] In another aspect of the disclosed technology, the first guide surface defines a single arc along its width.

[0075] In another aspect of the disclosed technology, the first guide surface defines a plurality of arcs along its width.

[0076] In another aspect of the disclosed technology, the width of the first guide surface is approximately equal to the width of the raw material when the raw material is in a substantially planar configuration.

[0077] In another aspect of the disclosed technology, the guide includes a textured and / or discontinuous surface on a portion proximate to and below the first guide surface.

[0078] In another aspect of the disclosed technology, the guide includes a second guide surface configured to guide the raw material into the chute when the raw material is in a twisted configuration.

[0079] In another aspect of the disclosed technology, the second guide surface is located between the inlet chute and the first guide surface.

[0080] In another aspect of the disclosed technology, the aperture is defined in part by the second guide surface.

[0081] In another aspect of the disclosed technology, the aperture is configured to receive the raw material while the raw material is in a twisted configuration.

[0082] In another aspect of the disclosed technology, the second guide surface is substantially linear.

[0083] In another aspect of the disclosed technology, the aperture extends through an upper surface of the guide; and the second guide surface is substantially perpendicular to the first guide surface.

[0084] In another aspect of the disclosed technology, the second surface is configured to bend the stock material by approximately 90 degrees.

[0085] In another aspect of the disclosed technology, the inlet chute defines an inlet opening for receiving the high density material, and the inlet opening has a width greater than a width of the aperture.

[0086] In another aspect of the disclosed technology, a dunnage conversion machine includes a drive mechanism having a first roller and a second roller, the first roller having an outer surface having a first shape and the second roller having an outer surface having a second shape different from the first shape. The first and second rollers are configured to convert a high-density raw material into a low-density dunnage.

[0087] In another aspect of the disclosed technology, the outer surface of the first roller is substantially smooth.

[0088] In another aspect of the disclosed technology, an outer surface of the second roller defines a protrusion configured to press the raw material against the outer surface of the first roller.

[0089] In another aspect of the disclosed technology, the protrusion includes a substantially planar surface configured to compress the raw material against the outer surface of the first roller.

[0090] In another aspect of the disclosed technology, the protrusions include tips configured to compress the raw material against the outer surface of the first roller.

[0091] In another aspect of the disclosed technology, the outer surface of the second roller includes a plurality of grooves, and the second roller includes a plurality of ridges disposed in the grooves.

[0092] In another aspect of the disclosed technology, an outer surface of the first roller comprises a substantially non-stick material.

[0093] In another aspect of the disclosed technology, the non-stick material includes silicone.

[0094] In another aspect of the disclosed technology, the first roller is in an idle state.

[0095] In another aspect of the disclosed technology, the drive mechanism further includes a motor configured to rotate the second roller during operation.

[0096] In another aspect of the disclosed technology, each ridge comprises an O-ring.

[0097] In another aspect of the disclosed technology, a first ridge of the plurality of ridges extends a first distance from the second roller, and a second ridge of the plurality of ridges extends a second distance from the second roller that is different than the first distance.

[0098] In another aspect of the disclosed technology, the first ridge is configured to press the raw material against the first roller with a first pressure, and the second ridge is configured to press the raw material against the first roller with a second pressure different from the first pressure.

[0099] In another aspect of the disclosed technology, the second pressure is approximately zero.

[0100] In another aspect of the disclosed technology, the plurality of ridges includes a third ridge extending from the second roller a third distance different from the second distance, and the second ridge is located between the first ridge and the third ridge.

[0101] In another aspect of the disclosed technology, the protrusion extends in a plane that is not perpendicular to the longitudinal axis of the second roller.

[0102] In another aspect of the disclosed technology, a system for producing dunnage includes: a dunnage conversion machine configured to transform raw material into dunnage; and a feed port including an inlet chute configured to direct raw material to the dunnage conversion machine. The inlet chute includes: a first lower interior surface; an inclined surface adjacent to and upstream of the first interior lower surface; a second lower interior surface adjacent to and upstream of the inclined surface; a first upper interior surface; and a second upper interior surface adjacent to and upstream of the first interior upper surface.

[0103] The first lower inner surface, the inclined surface, the second lower inner surface, the first upper inner surface, and the second upper inner surface define a channel extending between the inlet end and the outlet end of the chute. A portion of the channel defined between the first lower inner surface, the inclined surface, and the first upper inner surface is configured to gather raw materials. A portion of the channel defined between the second upper inner surface and the second lower inner surface is configured to guide the gathered raw materials to a position at the outlet end of the chute. BRIEF DESCRIPTION OF THE DRAWINGS

[0104] The following drawings illustrate specific embodiments of the present disclosure and are therefore not intended to limit the scope of the present disclosure. The drawings are not drawn to scale and are intended to be used in conjunction with the explanations in the following detailed description. The embodiments of the present disclosure will be described below in conjunction with the drawings, wherein the same reference numerals represent the same components.

[0105] Figure 1 is a rear top perspective view of a system for producing litter.

[0106] Figure 2 yes Figure 1 Top front perspective view of the system shown.

[0107] Figure 3 yes Figure 1 and Figure 2 0013] A rear top perspective view of the dunnage conversion machine and feed port of the system shown in 0013, with the feed port in a closed position.

[0108] Figure 4 yes Figure 1-3 A top front perspective view of a dunnage conversion machine and feed port shown in FIG. 1 , with the feed port in a closed position.

[0109] Figure 5 yes Figure 1-4 A rear top perspective view of a dunnage conversion machine and feed opening shown in , with the housing of the dunnage conversion machine removed and the feed opening in a closed position.

[0110] Figure 6 yes Figure 1-5 A top front perspective view of a dunnage conversion machine and feed opening shown in , with the housing of the dunnage conversion machine removed and the feed opening in a closed position.

[0111] Figure 7 yes Figures 1 to 5 A side front perspective view of a dunnage conversion machine and a feed opening shown in , with the housing of the dunnage conversion machine removed and the feed opening in an open position.

[0112] Figure 8 yes Figures 1 to 7 Top front perspective view of the feed port shown.

[0113] Fig. 9 yes Figures 1 to 8 Side view of the feed port shown.

[0114] Fig.10 yes Figures 1 to 9 Longitudinal cross-section of the feed port shown.

[0115] Fig.11 yes Figure 1-7 A top rear perspective view of a dunnage conversion machine shown in , with the outer shell and outlet chute of the dunnage conversion machine removed.

[0116] Fig.12 yes Figure 1-7 and 11 are top rear perspective views of the dunnage conversion machine shown in FIG. 11 with the housing, outlet chute and cutting motor assembly of the dunnage conversion machine removed.

[0117] Fig.13 yes Figure 1-7 , 11 and 12 are top rear perspective views of the dunnage conversion machine shown in FIGS. 1 and 12 with the housing, outlet chute, cutting motor assembly and cover of the dunnage conversion machine removed.

[0118] Fig.14 yes Figure 1-7 and Figure 11-13 An exploded side rear perspective view of a cutting assembly of a dunnage conversion machine is shown in FIG.

[0119] Fig.15 yes Fig.13 An exploded side front perspective view of the cutting assembly shown in FIG.

[0120] Fig.16 yes Fig.14 and 15 A rear view of the shuttle of the cutting assembly is shown in FIG.

[0121] Fig.17 yes Figure 14-16 A top view of the cutting portion and anvil portion of the cutting assembly shown in FIG.

[0122] Fig.18 yes Figure 1-7 and Figure 11-17 A rear view of a dunnage conversion machine shown in FIG. 1 with the housing, outlet chute, cutting motor assembly and cover of the dunnage conversion machine removed and depicting the cutting mechanism in a starting position.

[0123] Fig.19 yes Figure 1-7 and Figure 11-18 A rear view of a dunnage conversion machine shown in , with the housing, outlet chute, cutting motor assembly and cover of the dunnage conversion machine removed, and depicting the cutting mechanism in an intermediate position.

[0124] Fig. 20 yes Figure 1-7 and Figure 11-19 A rear view of a dunnage conversion machine is shown in FIG. 1 with the housing, outlet chute, cutting motor assembly and cover of the dunnage conversion machine removed and depicting the cutting mechanism in a terminal position.

[0125] Fig.21 and 22 yes Figure 1-7 and a rear top perspective view of the dunnage conversion machine shown in 11-20 with the housing, outlet chute, cutting motor assembly and cover of the dunnage conversion machine removed, and depicting the cutting mechanism removed in a starting position.

[0126] Fig.23 and 24 yes Figure 1-7 and a rear top perspective view of the dunnage conversion machine shown in 11-22 with the housing, outlet chute, cutting motor assembly and cover of the dunnage conversion machine removed, and depicting the cutting mechanism removed when the cutting mechanism is in a terminal position.

[0127] Fig.25 yes Figures 1 to 24 A top perspective view of the rollers of the drive mechanism of the dunnage conversion machine shown in FIG.

[0128] Fig.26 yes Figures 1 to 25 A top perspective view of another roller of the drive mechanism of the dunnage conversion machine is shown in FIG.

[0129] Fig. 27 yes Figures 1 to 26 A top perspective view of the spine of the drive mechanism of the dunnage conversion machine shown in FIG.

[0130] Fig.28 yes Figures 1 to 27 A cross-sectional view of the rollers and ridges of the drive mechanism of a dunnage conversion machine is shown.

[0131] Fig.29 yes Figure 1 and Figure 2 A top rear perspective view of an alternative embodiment of the illustrated system.

[0132] Fig.30 yes Fig.29 Top front perspective view of the system shown.

[0133] Fig.31 yes Figure 1-28 A top front perspective view of a dunnage conversion machine and feed opening shown in , showing raw material being drawn into the feed opening from a roll of raw material. DETAILED DESCRIPTION

[0134] The following discussion omits or only briefly describes conventional features of the disclosed technology that are obvious to those skilled in the art. Reference to various embodiments does not limit the scope of the claims appended hereto. In addition, any examples set forth in this specification are not limiting and only set forth some of the many possible embodiments of the appended claims. In addition, the specific features described herein can be used in combination with other described features in various possible combinations and arrangements. Those of ordinary skill in the art will know how to use the present invention, in conjunction with routine experimentation, to achieve the embodiments or other results not specifically disclosed in the embodiments.

[0135] Unless otherwise expressly defined herein, all terms should be given the broadest possible interpretation, including the meaning implied by the specification and the meaning understood by those skilled in the art and / or the meaning defined in dictionaries, papers, etc. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art disclosed. It must also be noted that, as used in the specification and the appended claims, the singular forms "a", "an" and "the" include plural referents unless otherwise specified, and the terms "including" and / or "comprising" when used in this specification specify the presence of the features, components and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, components, parts and / or groups thereof. In addition, methods, devices and materials similar or equivalent to those described herein can also be used to practice or test the disclosed technology.

[0136] Various examples of the disclosed technology are provided in this disclosure. The use of these embodiments is illustrative only and does not limit the scope and meaning of the present invention or any example form in any way. Similarly, the present invention is not limited to any specific preferred embodiment described herein. In fact, it is obvious to those skilled in the art that after reading this specification, the present invention can be modified and changed, and can be modified and changed without departing from the spirit and scope of the disclosed technology. Therefore, the present invention is limited only by the terms of the claims and the full scope of equivalent schemes given by the claims.

[0137] As used herein, the terms "substantially" and "substantially equal" indicate that an equal relationship is not a strict relationship and does not exclude functionally similar variations. Unless otherwise indicated by the context or description, the use of the terms "substantially" or "substantially equal" when describing two or more dimensions indicates that the equal relationship between the dimensions includes variations that do not change the least significant digits of the dimensions using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.). As used herein, the term "substantially parallel" indicates that a parallel relationship is not a strict relationship and does not exclude functionally similar variations. As used herein, the term "substantially orthogonal" indicates that an orthogonal relationship is not a strict relationship and does not exclude functionally similar variations.

[0138] A system for converting high density raw material into low density padding is disclosed. The raw material is processed by a longitudinal crimping machine to form longitudinal creases in the raw material to form the padding, or by a transverse crimping machine to form transverse creases in the raw material. A supply unit of raw material may be stored in roll form (whether drawn from the inside or outside of the roll), in coil form, in a fan-folded source, or in other suitable forms. The raw material may be continuous or perforated. The conversion device feeds the raw material from the supply unit in a first direction, which may be an anti-run-out direction.

[0139] The raw material can be any suitable type of protective packaging material, including, for example, flat or rolled paper materials, other padding and void filling materials, inflatable packaging pillows, etc. Some embodiments can use a sheet of other paper or fiber-based material sources. Other embodiments can use a source of wound fiber materials (such as ropes or wires). Other embodiments can use thermoplastic materials, such as rolls of plastic materials that can be used to form pillow packaging materials. Examples of paper materials used include fan-folded supply units of raw materials with a 30-inch lateral width and / or a 15-inch lateral width. Preferably, these sheets are folded into a single layer. In other embodiments, multiple layers of sheets can be fan-folded together so that the padding is made of superimposed sheets that are crumpled together during the conversion process.

[0140] Any suitable raw material may be used. For example, the raw material may have a basis weight of about 20 pounds to about 100 pounds. The raw material may include paper raw material stored in a high-density configuration having a first longitudinal end and a second longitudinal end and subsequently converted by a conversion system to a low-density configuration. The raw material may be, for example, Figure 1 and Figure 2 The sheet material strip stored in the folded structure shown; or Fig.29 and Fig.30 A strip of sheet material stored in a coreless roll is shown. The raw material can be formed or stored as a single layer or a multi-layer material. When a multi-layer material is used, a layer can include multiple laminates. Other types of materials can be used, such as pulp-based virgin and recycled paper, newsprint, cellulose and starch combinations, and polymeric or synthetic materials of appropriate thickness, weight and size.

[0141] In some embodiments, the supply unit of the raw material can have a folding fan-shaped configuration. For example, a foldable material (such as paper) can be folded repeatedly to form a stack or a three-dimensional body. The term "three-dimensional body" is opposite to a "two-dimensional" material, which has three dimensions, and each dimension is not negligible. A continuous sheet (such as paper, plastic or foil) can be folded at multiple folding lines, which extend transversely to the longitudinal direction of the continuous sheet, or extend transversely to the feeding direction of the sheet. For example, folding a continuous sheet with a substantially uniform width along a transverse fold line can form or define sheet portions with substantially the same width. The continuous sheet can be folded in sequential, opposite or alternating directions to produce an accordion-shaped continuous sheet. For example, the folded portion can form or define portions along the continuous sheet, and these portions can be substantially rectangular.

[0142] For example, sequentially folding a continuous sheet can produce an accordion-shaped continuous sheet, in which the sheet portions have substantially the same size and / or shape as each other. A plurality of adjacent portions defined by fold lines can be substantially rectangular and can have the same first size (e.g., a size corresponding to the width of the continuous sheet) and substantially the same second size along the longitudinal direction of the continuous sheet. For example, when adjacent portions are in contact with each other, the continuous sheet can be configured as a three-dimensional body or stack, in the shape of an accordion formed by folding and compressed, so that the continuous sheet forms a three-dimensional body or stack.

[0143] The fold lines of the raw material may have any suitable orientation relative to each other and to the longitudinal and transverse directions of the continuous sheet. In addition, the raw material units may have transverse folds that are parallel to each other. For example, the portion formed by the fold lines may be compressed to form a three-dimensional body in the form of a cuboid. In addition, the raw material may have one or more folds that are not parallel to the transverse folds.

[0144] The raw material can be provided in the form of any suitable number of discrete raw material units. In some embodiments, two or more raw material units can be connected together to continuously feed the material into the padding conversion machine. The material can be fed sequentially or simultaneously (i.e., serially or in parallel) from the connected raw material units. The raw material units can have various suitable sizes and configurations, and can include stacks or rolls of one or more suitable sheet materials. The term "sheet material" refers to a material that is generally sheet-like and two-dimensional, that is, the two dimensions of the material are significantly larger than the third dimension, so that the third dimension can be negligible or insignificant compared to the other two dimensions. In addition, the sheet material can be generally flexible and foldable, such as the exemplary materials described herein.

[0145] The raw material unit may include an attachment mechanism to connect multiple raw material units, for example, to create a continuous material feed from multiple discrete raw material units. The respective ends and starting ends of adjacent rolls may be connected by adhesive or other suitable means to facilitate daisy-chaining the rolls together to form a continuous stream of sheet material that can be fed to a dunnage conversion machine.

[0146] Folding the continuous sheet along the transverse fold line may form or define a substantially rectangular sheet portion. The rectangular sheet portions may be stacked together, for example, by folding the continuous sheet in alternating directions to form a three-dimensional body having longitudinal, transverse and vertical dimensions. The raw material from the raw material unit may be fed through a feed port (e.g. Figure 1-10 The continuous raw material sheet may be fed into the feed opening 100 as shown. In some applications, the lateral dimension of the continuous raw material sheet may be larger than one or more dimensions of the feed opening. For example, the lateral dimension of the continuous sheet may be larger than the diameter of the substantially circular feed opening. Reducing the width of the continuous sheet in this manner at the beginning of the conversion process may facilitate its entry into the feed opening. The reduced width of the leading portion of the continuous sheet may facilitate smoother entry and / or transition of daisy-chained continuous sheets and / or may reduce or eliminate jamming or tearing of the continuous sheet. In addition, reducing the width at the beginning of the continuous sheet may facilitate connecting two or more raw material units together or in a daisy-chained form. For example, a smaller connector or engaging element than would otherwise be required may be used to achieve the connection or daisy-chaining of materials having tapered portions. In addition, tapered portions may be easier to manually align and / or connect together than full-width sheet portions.

[0147] Figure 1 and Figure 2 An embodiment of a system for producing dunnage 10 is depicted. System 10 is configured to process raw material 19 into dunnage 15. System 10 includes a supply unit 18 of raw material 19 and dunnage equipment 50.

[0148] The dunnage equipment 50 includes a dunnage conversion machine 60 , a support 12 configured to support the dunnage conversion machine 60 , and a supply station 13 configured to accommodate a supply unit 18 of a raw material 19 .

[0149] The specific configuration of the support member 12 shown in the figures is disclosed for illustration purposes only. The support member 12 may have other configurations suitable for supporting the dunnage conversion machine 60.

[0150] same, Figure 1 and Figure 2 The rack or basket type configuration of the supply station 13 shown in the figure is disclosed for illustration purposes only, and the supply station 13 accommodates the supply unit 18 in the form of a stack of folded raw materials 19. The supply station 13 can have other configurations suitable for supporting the supply unit 18, for example, a single bundle configuration; a multi-bundle daisy chain configuration; a flat configuration; a rolled configuration; and / or a curved configuration.

[0151] For example, Fig.29 and Fig.30 An alternative embodiment of the system 10 is shown in the form of a system for producing dunnage 10a. The system 10a includes a supply station 13a configured to receive a supply unit 18a of a roll of raw material 19. In other alternative embodiments, the supply station 13 may be a cart (not shown) movable relative to the dunnage conversion machine 60. In other embodiments, the supply station 13 may be a basket (e.g., Figure 1 and 2 13 ), a rack or other type of support structure mounted on the support 12. In such embodiments, the dunnage conversion machine 60 and the supply station 13 do not move relative to each other. In other embodiments, the supply station 13 and the dunnage conversion machine 60 may be fixed relative to each other but not mounted to each other. In other alternative embodiments, the supply station 13 and the dunnage conversion machine 60 may be configured to move relative to each other with or without being mounted together.

[0152] The supply station 13 may support one or more supply units 18 of raw material 19 . Figure 1 A to Figure 1 C shows a supply station 13 supporting a plurality of supply units 18. In applications where the supply station 13 accommodates a plurality of supply units 18, the end sheets and the start sheets of adjacent supply units 18 are connected together before or after being placed on the supply station 13. Connecting a plurality of supply units together or in a daisy chain form allows for a continuous supply of raw material 19.

[0153] The raw material 19 is converted into the padding material 15 through the system 10 along the material path A, such as Figure 1 and Figure 2 The material path A has an inlet end, from which the raw material 19 is supplied to the system 10, and an outlet end, from which the padding material 15 leaves the system 10.

[0154] Figures 3 to 8 A dunnage conversion machine 60 of the system 10 is depicted. Figure 3 and Figure 4 As shown, the dunnage conversion machine 60 includes a housing 61 , a feed port 100 , an outlet chute 62 , a cutting motor assembly 201 , and a feed motor 301 extending from the housing 61 .

[0155] For ease of explanation, Figure 5 and Figure 6 The dunnage conversion machine 60 is shown without the housing 61, thereby exposing the frame 63 and cutting mechanism 200 of the dunnage conversion machine 60. Figure 5 and Figure 6 As shown, the feed port 100 is rotatably coupled to the frame 63 via the inlet spindle 65. Specifically, the feed port 100 defines a channel 131 (in Figure 8-10 ), which is aligned with a channel (not shown) defined by the frame 63. The channel 131 and the channel defined by the frame 63 receive the inlet spindle 65. Figure 7 The feed port 100 is shown to rotate upward about the inlet main axis 65, from Figure 1-6 The closed or lowered position shown is Figure 7 The ability to rotate the feed port 100 upward in this manner allows a user to clear material that may become stuck or otherwise obstruct the outlet portion of the feed port 100 .

[0156] The dunnage conversion machine 60 also includes a drive assembly 300 such as Figure 7 The drive assembly 300 includes a feed motor 301 and rollers 310, 320 driven by the feed motor 301. The rollers 310, 320 are configured to drive the raw material 19 through the dunnage conversion machine 60 and convert the raw material 19 into dunnage.

[0157] The dunnage conversion machine 60 is configured to reverse the direction of travel of the raw material 19 as the raw material 19 moves through the dunnage conversion machine 60. The ability to reverse the direction of travel of the raw material 19 allows the converted dunnage material exiting the dunnage conversion machine 60 to be pulled against certain types of cutting equipment with which the dunnage conversion machine 60 may be equipped, which in turn may assist the cutting mechanism in cutting the dunnage material.

[0158] refer to Figures 8 to 10, the feed port 100 includes a guide 110, an inlet chute 120, and an outlet plate 130. The guide 110 is adjacent to the front end or upstream end of the inlet chute 120. The guide 110 and the inlet chute 120 may be formed integrally. Alternatively, the guide 110 and the inlet chute 120 may be formed separately and may be connected by a suitable device such as a fastener so that the guide 110 may be removably connected to the inlet chute 120. The removable configuration allows the guide 110 to be removed from the inlet chute 120 when the raw material 19 is fed to the inlet chute 120, for example, when bending the raw material 19 is not required or desired. Therefore, allowing the guide 110 to be removed can improve the user's ability to customize the way the raw material 19 is bent when fed to the inlet chute 120.

[0159] The outlet plate 130 is adjacent to the rear end or downstream end of the inlet chute 120. The outlet plate 130 and the inlet chute 120 may be integrally formed. Alternatively, the outlet plate 130 and the inlet chute 120 may be formed separately and may be connected by suitable means such as fasteners.

[0160] The inlet chute 120 has a mouth 121 that defines an inlet end 101 for receiving the raw material 19. The outlet plate 130 defines the outlet end 102 through which the raw material 19 passes when it exits the feed port 100 while traveling along the material path A. The outlet plate 130 is configured to secure the feed port 100 to the frame 63. More specifically, the outlet plate 130 defines a channel 131 that receives the spindle 65 that couples the feed port 100 to the frame 63.

[0161] The guide 110 is configured to receive the raw material 19 as the raw material 19 is fed to and passes through the inlet chute 120. The guide 110 extends from a lower portion of a mouth 121 of the inlet chute 120 such that an upper surface 112 of the guide 110 and a first lower surface 122 of the inlet chute 120 define a substantially planar surface for feeding the raw material 19 along a material path A. Thus, the material path A along the upper surface 112 of the guide 110 and the first lower surface 122 of the inlet chute 120 is substantially straight when viewed from the side. In addition, the raw material 19 travels substantially in a horizontal direction and does not change in orientation when moving on the upper surface 112 and the first lower surface 122 of the guide 110.

[0162] As used herein, the term "substantially planar surface" may refer to a surface that is so smooth that it appears to be completely flat. For example, a "substantially planar surface" may be a completely flat surface. In addition, a "substantially planar surface" may be a surface having a large radius of curvature, such as ten feet or more.

[0163] Although the guide 110 is depicted as extending from the inlet chute 120 such that the upper surface 112 of the guide 110 and the first lower surface 122 of the inlet chute 120 are parallel, in other embodiments, the guide 110 may extend from the inlet chute 120 at an angle such that the upper surface 112 of the guide 110 and the first lower surface 122 of the inlet chute 120 are angled relative to each other. In this configuration, the material path A along the upper surface 112 of the guide 110 and the first lower surface 122 of the inlet chute 120 is not linear.

[0164] The guide member 110 may extend from the inlet chute 120 at an upward or downward angle. When the guide member 110 extends from the inlet chute 120 at a downward angle, the raw material supplied through the top of the guide member 100 may be further broken up by the bend created between the first lower surface 122 of the inlet chute 120 and the upper surface 112 of the guide member 110. The bend may make the raw material 19 more flexible, thereby being more conducive to conversion into a dunnage material.

[0165] The guide member 110 also has a first guide surface 113, such as Figures 8 to 10 As shown. The first guide surface 113 is adjacent to the upper surface 112 of the guide member 110 and forms the upstream end of the guide member 110. The first guide surface 113 has a substantially arcuate shape when viewed from above, so that the raw material 19 supplied on the first guide surface 113 is bent around multiple axes to form a complex curve. This curvature can make the raw material 19 easier to bend to be converted into a pad, and is particularly suitable for the case where the raw material 19 is supplied to the feed port 100 in a substantially flat form, for example, Figure 1 and Figure 2 As shown, a raw material 19 is supplied from a supply unit 18, wherein the sheet material 18 is folded, and adjacent folds are stacked.

[0166] The first guide surface 113 defines a single arc along its width or lateral dimension. In alternative embodiments, the guide surface 113 may be shaped to define multiple arcs so that the raw material 19 fed over the guide surface 113 may be bent at multiple points on the raw material 19. Depending on the desired shape of the dunnage to be produced, such additional bends may make the raw material 19 easier to convert into certain types of dunnage. For example, the multiple bends in the raw material due to the multiple arcs of the guide surface 113 may make it easier to wrinkle or bend when converted into dunnage.

[0167] In other alternative embodiments, the guide surface 113 can have a non-arc shape. For example, although the first guide surface 113 is depicted as being substantially non-angled as a means of avoiding tearing of the stock material, in other embodiments, the first guide surface 113 can have a greater angle. Such an angle can help form bends in certain types of thicker stock material 19 that would otherwise not be able to bend with the non-angled first guide surface 113. In other alternative embodiments, the first guide surface 113 can be configured with a sharp point to create a more defined bend when the stock material 19 is fed over the first guide surface 113.

[0168] The first guide surface 113 may have a width or lateral dimension that is substantially similar to the width of the raw material 19 before the raw material 19 is deformed by the dunnage conversion machine 60. This characteristic of the first guide surface 113 allows the guide 110 to maintain constant contact with the raw material 19, which in turn may result in more accurate guidance of the raw material 19 into the inlet chute 120. In alternative embodiments where precise guidance is not required, the width of the first guide surface 113 may be different than the width of the raw material 19.

[0169] The guide 110 has a textured or discontinuous surface 114 on a portion of the guide 110 located adjacent to and below the first guide surface 113. Figure 8-10 As shown, the discontinuity in surface 114 is defined by a recess or indentation extending inwardly from surface 114 into guide 110. Such a discontinuity in surface 114 may help a user to more securely grasp guide 110 by increasing friction between surface 114 and the user's hand.

[0170] The guide 110 defines an aperture 111 such as Figure 8 The aperture 111 extends through the upper surface 112 and is configured to allow the raw material 19 to pass therethrough when the raw material 19 is fed to the dunnage conversion machine 60. The guide 110 also includes a second guide surface 115, such as Figure 8 As shown. The raw material 19 passes through the orifice 111 and travels onto the second guide surface 115. For example, in some embodiments, the second guide surface 115 can be configured to contact the raw material 19 in a non-planar state. For example, Fig.31 The raw material 19 is shown passing through the second guide surface 115 in a twisted configuration while being fed upwardly through the orifice 111 from the supply unit 18 in the form of a raw material roll 19 .

[0171] The second guide surface 115 may be shaped so that the raw material 19 is more ductile when the raw material 19 is fed over the second guide surface 115. Figure 8As shown, the second guide surface 115 has an acute angle, i.e., a 90 degree bend, because the raw material 19 generally passes through the second guide surface 115 in a non-planar configuration; therefore, a relatively sharp surface is required to bend the raw material 19 so that it is more ductile to be converted into a pad. In an alternative embodiment, the second guide surface 115 can be smooth to allow thinner raw materials to travel over the second guide surface without bending.

[0172] The second guide surface 115 is configured to accommodate a raw material 19 having a width or lateral dimension that is smaller than the width of the raw material 19 that can be fed to the dunnage conversion machine 60 via the first guide surface 113. Therefore, the second guide surface 115 requires a smaller width than the first guide surface 113 to maintain constant contact with the raw material 19. Therefore, the width or lateral dimension of the second guide surface 115 is smaller than the width of the first guide surface 113.

[0173] The second guide surface 115 is substantially linear to reduce the possibility of the non-planar raw material 19 catching the edge of the second guide surface 115 and tearing when it is fed on the second guide surface 115. In alternative embodiments, the second guide surface can be non-linear. For example, the second guide surface 115 can have an arcuate profile similar to the first guide surface 113 to facilitate the raw material 19 to bend when passing through the second guide surface 115. In other embodiments, the second guide surface 115 can be arcuate in the opposite direction of the first guide surface to better keep the raw material 19 in a desired position, such as at the centerline of the feed port 100.

[0174] The guide 110 is depicted as having one orifice 111. In alternative embodiments, the guide 110 may include multiple orifices 111. For example, in applications where multiple streams of raw material 19 are fed to the inlet chute 120, each orifice 111 may accommodate a respective stream of raw material.

[0175] See also Fig.10 , the inlet chute 120 further includes a top wall 123 and a bottom wall 124. The top wall 123 includes a first upper inner surface 126 and a second upper inner surface 140. The first upper inner surface 126 extends between the inlet end 101 of the inlet chute 120 and the second upper inner surface 140. The second upper inner surface 140 extends between the first upper inner surface 126 and the outlet end 102 of the inlet chute 120.

[0176] The bottom wall 124 has a first lower inner surface 122, a second lower inner surface 141, and an inclined surface 128. The first lower inner surface 122 extends between the inlet end 101 of the inlet chute 120 and the inclined surface 128. The inclined surface 128 extends between the first lower inner surface 122 and the second lower inner surface 141. The second lower inner surface 141 extends between the inclined surface 128 and the outlet end 102 of the inlet chute 120.

[0177] Still refer to Fig.10 The first lower inner surface 122, the second lower inner surface 141, the inclined surface 128, the first upper inner surface 126, and the second upper inner surface 140 partially define an internal passage 132 within the inlet chute 120. The passage 132 receives the raw material 19 and guides the raw material 19 to travel between the inlet end 101 and the outlet end 102 of the inlet chute 120.

[0178] The first lower interior surface 122 is substantially planar and substantially smooth. This feature can reduce or eliminate the possibility of the raw material 19 becoming blocked or caught when the raw material 19 is fed through the inlet chute 120. The inclined surface 128 is substantially planar and provides a smooth transition between the first lower interior surface 122 and the second lower interior surface 141. In an alternative embodiment, the inclined surface 128 may have a profile consisting of a curve to provide a smoother transition from the inclined surface 128 to the second lower interior surface 141.

[0179] The portion of the passage 132 defined between the second upper inner surface 140 and the second lower inner surface 141 can be shaped and positioned to direct the raw material 19 into the dunnage conversion machine 60. Specifically, the second upper inner surface 140 and the second lower inner surface 141 correspond to the portion of the passage 132 within the inlet chute 120 having the narrowest width or lateral dimension, such as Figure 8 The width and height of the portion of the inlet chute 120 near its outer end 102 are relatively low compared to the corresponding width and height of the portion of the inlet chute 120 near the inlet end 101, which allows raw materials to be fed into the inlet chute 120 without using a separate guide.

[0180] Thus, the portion of the channel 132 defined between the first lower inner surface 122, the inclined surface 128, and the first upper inner surface 126 is configured to gather the raw material 19 supplied into the inlet chute 120; and the portion of the channel 132 defined between the second upper inner surface 140 and the second lower inner surface 141 is configured to concentrate the gathered raw material 19 to a relatively precise position at the outlet end 102 without the need for a guide.

[0181] refer to Fig.10, the bottom wall 124 may include a radio frequency identification (RFID) device 129 located below the surfaces 128, 141 and adjacent to the outlet end 102. The RFID device 129 is configured to provide an indication to a controller (not shown) of the dunnage conversion machine 60 when the feed port 100 is in its closed position and when it is not in its closed position. The controller is configured to allow activation of the dunnage conversion machine 60 only when the feed port 100 is in the closed position, i.e., the controller is configured to prevent activation of the dunnage conversion machine 60 when the feed port 100 is in its open position to help enhance the safety of the user and others near the dunnage conversion machine 60.

[0182] In an alternative embodiment, first lower interior surface 122 , second lower interior surface 141 , and angled surface 128 of bottom wall 124 may be formed as a single substantially planar surface to help reduce the likelihood of raw material 19 becoming blocked or otherwise snagged while passing through inlet chute 120 .

[0183] See also Fig.10 , a portion of the first upper inner surface 126 of the top wall 123 forms a protrusion 125 that extends downward toward the bottom wall 124. The protrusion 125, together with an opposing portion of the first lower inner surface 122 of the bottom wall 124 opposite the protrusion 125, defines a restriction 127. The restriction 127 allows the raw material 19 to be fed through the inlet chute 120 while preventing foreign objects from entering through the inlet chute 120. Specifically, the size of the restriction 127 allows the raw material 19 to pass through the inlet chute 120 while restricting thicker objects from moving past the restriction 127 along the material path A. For example, when a user uses his or her hand to feed the raw material 19 to and through the inlet chute 120, the relatively narrow restriction 127 will prevent the user's fingers from moving past the restriction 127 and further into the inlet chute 120. Therefore, the restriction 127 acts as a safety device that can reduce or eliminate the possibility of the user's fingers and hands being inadvertently caught in the dunnage conversion machine 60. Additionally, the restriction 127 may prevent other objects from reaching the dunnage conversion machine 60 through the inlet chute 120 , thereby reducing the likelihood of damage to the dunnage conversion machine 60 due to the ingestion of objects other than the raw material 19 .

[0184] The protrusion 125 may be formed as part of the bottom wall 124 and in alternative embodiments may extend toward the top wall 123. For example, such a configuration may be used in embodiments where the raw material 19 is fed into the feed port 100 from above the feed port 100 and travels along the top wall 123 of the inlet chute 120. In these types of embodiments, the inner surface of the top wall 123 may be substantially planar, while the bottom wall 124 defines a protrusion 125 that extends into the channel 132 to define the restriction 127.

[0185] like Fig.10As shown, the protrusion 125 is closer to the inlet end 101 of the inlet chute 120 than to the outlet end 102. In alternative embodiments, the protrusion 125 may be positioned closer to the outlet end 102 than to the inlet end 101. For example, in applications where a greater degree of guidance is desired when inserting the raw material 19 into the inlet chute 120, the protrusion 125 may be located closer to the outlet end 102. This feature allows the user to guide the raw material 19 further down the channel 132 while still providing a restriction to prevent the user from inserting their hand all the way into the inlet chute 120. Additionally, in this configuration, the protrusion 125 may be positioned closer to the outlet end 102 than to the inlet end 101. Fig.10 Compared to the configuration of the protrusion 125 shown in , the angle of the portion of the first upper inner surface 126 forming the upstream side of the protrusion 125 relative to the horizontal direction is smaller than the angle of the portion of the first upper inner surface 126 forming the downstream side of the protrusion 125 relative to the horizontal direction.

[0186] Still refer to Fig.10 , the protrusion 125 is substantially composed of a curve. In an alternative embodiment, the protrusion 125 may have a triangular cross-section, so that the lowest portion of the protrusion 125 forms a tip. It is worth noting that the tip can be particularly effective in preventing foreign matter from passing through the inlet chute 120.

[0187] exist Fig.10 In the illustrated embodiment, the portion of the first upper inner surface 126 that forms the upstream side of the protrusion 125 is angled at a greater angle relative to the horizontal direction than the portion of the first upper inner surface 126 that forms the downstream side of the protrusion 125. In alternative embodiments, the upstream and downstream sides of the protrusion 125 may be the same, or may be the same. Fig.10 In addition, the height or vertical dimension of the protrusion 125 can be the opposite of Fig.10 The difference shown in .

[0188] Figure 11-13 The cutting mechanism 200 of the dunnage conversion machine 60 is depicted coupled to a frame 63. For clarity of illustration, Figure 11-13 Certain components of the dunnage conversion machine 60 are not shown. Specifically, Fig.11 The cutting mechanism 200 and frame 63 are depicted without the housing 61 and the exit slot 62 . Fig.12 The cutting mechanism 200 and frame 63 are shown without the housing 61 , outlet chute 62 and cutting motor assembly 201 . Fig.13 The cutting mechanism 200 and frame 63 are shown without the housing 61 , outlet chute 62 , cutting motor assembly 201 , and cover 210 of the dunnage conversion machine 60 . Fig.14 and Fig.15 is an exploded view of the cutting mechanism 200 .

[0189] The cutting mechanism 200 includes a cutting motor assembly 201 , a cover 210 , a crank 202 , a shuttle 230 , a magnet 203 , a cutting portion 220 , and an anvil portion 240 .

[0190] like Fig.14 and 15 As shown, the cover 210 defines: a recess 212 for receiving the crank 202; a hole 213 for receiving the components of the cutting motor assembly 201; and a plurality of holes 214 for receiving fasteners. The cover 210 also includes a side wall 215 (at Figure 18-24 ), which together with the cover 210 defines a space for receiving the shuttle 230.

[0191] Still refer to Fig.14 and 15 The cutting motor assembly 201 includes a motor body 207 and a motor extension 205 extending from the motor body 207. The crank 202 includes a crank arm 204 and a leg 208, and the leg 208 defines a hole 206 between the crank arm 204 and the leg 208.

[0192] The cutting motor assembly 201, the cover 210, and the crank 202 are assembled by inserting the motor extension 205 into the hole 213 in the cover 210; and connecting the motor body 207 to the cover 210 using fasteners that are inserted into the aperture 214 in the cover 210 and engage the motor body 207. The crank 202 is connected to the cutting motor assembly 201 by inserting the crank 202 into the recess 212 in the cover 210 and inserting the motor extension 205 into the hole 206 in the crank 202. The legs 208 defining the hole 206 are compressed together to secure the crank 202 to the motor extension 205 so that rotation of the motor extension 205 will transmit corresponding rotation to the crank 202.

[0193] As described below, the shuttle 230 is configured to engage the cutting portion 220 so that movement of the shuttle 230 imparts corresponding movement to the cutting portion 220. Fig.16 , the shuttle 230 includes a mating feature, for example, a mating feature in the form of an arm or protrusion 233, which couples the shuttle 230 to the cutting portion 220. The protrusion 233 has a base 236 and a wing 235. The wing 235 extends laterally from the base 236 at a substantially perpendicular angle relative to the base 236. In alternative embodiments, the wing 235 can extend from the base 236 at other angles (e.g., about 10 degrees to about 80 degrees). In addition, alternative embodiments of the protrusion 233 may have less than or more than two wings 235. The protrusion 233 may include, for example, one wing 235 to help minimize manufacturing costs. For example, more than two wings 235 may be used to enhance the engagement between the protrusion 233 and the cutting portion 220.

[0194] The protrusion 233 is integrally formed with the rest of the shuttle 230. In alternative embodiments, the protrusion 233 can be removed from the rest of the shuttle 230, for example, to provide greater customizability to the user by allowing the user to select a particular design of the protrusion 233.

[0195] In other alternative embodiments, a protrusion 233 may be formed on the cutting portion 220, and the shuttle 230 may have an opening configured to receive the protrusion 233. This feature may allow the cutting portion 220 to have more material along its central portion, for example, to increase the structural integrity of the cutting portion 220. In addition, the shuttle 230 may be configured with additional engagement features, such as additional recesses and magnets disposed in the recesses, to increase engagement of the shuttle 230 with a backing surface (described below).

[0196] like Fig.16 As shown, the shuttle 230 includes side walls 237 defining an opening 238 therebetween. The opening 238 is configured to receive the cutting portion 220. The side walls 237 can help enhance the lateral stability of the cutting portion 220 relative to the shuttle 230.

[0197] See also Fig.14 and Fig.15 , the cutting portion 220 defines a receiving slot 221 that is configured to receive a protrusion 233 of the shuttle 230. The size and shape of the receiving slot 221 enables the protrusion 233 to fit within the receiving slot 221 with minimal clearance. The engagement of the protrusion 233 with the cutting portion 220, together with the cutting portion 220 and the sidewall 237, restricts the relationship of the cutting portion 220 relative to the shuttle 230. For example, the base 236 helps restrict the movement of the cutting portion 220 relative to the shuttle 230 in a first direction, i.e., lateral movement, while the wing 235 helps restrict the movement of the cutting portion 220 relative to the shuttle 230 in a second direction different from the first direction, i.e., along the cutting direction B and along the cutting plane, as discussed further below. In this way, movement of the shuttle 230 causes the cutting portion 220 to move.

[0198] like Fig.16 As shown, the shuttle 230 defines a track, for example, in the form of a linear guide slot 231. The shuttle 230 also includes an entry opening to the guide slot, for example, in the form of an entrance slot 234. The guide slot 231 is used to receive the end of the crank arm 204 of the crank 202 so that the crank arm 204 can translate between the ends of the guide slot 231. Therefore, the guide slot 231 defines a linear axis along which the crank arm 204 can translate. The entrance slot 234 extends in a direction transverse to the axis of the guide slot 231. The entrance slot 234 extends between one side of the shuttle 230 and the guide slot 231. Therefore, the entrance slot 234 facilitates the crank arm 204 to enter and exit the guide slot 231.

[0199] See also Fig.14 , the cutting portion 220 defines a recess 222. The recess 222 is configured to receive the magnet 203 of the cutting mechanism 200 so that the magnet 203 can apply a magnetic force that holds the cutting portion 220 against a backing surface, i.e., a backing surface 243 of the anvil portion 240, which is mounted on the frame 63 and when the cutting portion 222 and the shuttle 230 are moved along Fig.17 243, the cutting portion 220 remains stationary relative to the cutting portion 222 and the shuttle 230 when the cutting portion 222 moves in the cutting direction B indicated in FIG. 243. The magnetic force helps to keep the cutting portion 220 flush with the backing surface 243 as the cutting portion 222 slides along the backing surface 243 in the cutting direction. When the backing surface is substantially planar, such as the backing surface 243, the engagement of the cutting portion 220 with the backing surface causes the cutting portion 220 to translate along the cutting plane. Thus, when the cutting portion 220 is engaged with the shuttle 230 in the manner described above, and the magnet 203 magnetically couples the cutting portion 220 to the anvil portion 240, the cutting portion 220 is linearly driven along the cutting direction B by the movement of the shuttle 230.

[0200] In alternative embodiments, the cutting portion 220 can have a different number of recesses and a different number of corresponding magnets 203 than disclosed herein. For example, some embodiments can include only a single recess for a single magnet to help minimize manufacturing costs. Other embodiments can include more than two recesses and more than two magnets to increase the magnetic force that couples the cutting portion 220 to the anvil portion 240. In other alternative embodiments, the cutting portion 220 and the anvil portion 240 can be configured such that the cutting portion 220 is fixed, while the shuttle 230 carries the anvil portion 240 and moves the anvil portion 240 relative to the cutting portion 220 in a cutting direction.

[0201] The cutting portion 220 is configured as a blade including a cutting edge 223, such as Fig.14 , 18 24. The front end of the cutting edge 223 has a sharp tip, which helps the cutting edge 223 to effectively start cutting. In alternative embodiments, the front end can have other shapes. For example, the leading edge can have a curved tip to avoid applying excessive pressure on a relatively small area of ​​the pad being cut.

[0202] In alternative embodiments, the cutting edge 223 may have a rounded or blunt tip to initiate cutting. For example, when the cutting portion 220 pushes the pad against an opposing surface with a sharp edge (e.g., an anvil with a sharp edge), the cutting portion 220 may cut the pad without a sharp edge on the cutting portion 220, provided that the cutting portion 220 moves at a sufficient speed to cut the pad. In other alternative embodiments, the cutting edge 223 may be serrated and may be equipped with a plurality of teeth, an edge with shallow teeth, or other configurations. The plurality of teeth are defined by points separated by grooves located therebetween.

[0203] The cutting edge 223 is depicted as having a single tip that forms the leading end of the cutting edge 223. In alternative embodiments, the cutting edge 223 may include more than one tip to facilitate easier cutting of the pad material. The tips may be staggered so that there are one or more leading tips and multiple trailing tips. Alternatively, the tips may be configured so that all tips are equally aligned and there are no leading or trailing tips.

[0204] The cutting edge 223 is arranged symmetrically about the tip of the cutting edge 223, so that the cutting edge 223 includes two substantially identical halves. Fig.14 , 18 24, each half is substantially straight and angled relative to the direction of travel of the cutting edge 223 so that when the cutting edge 223 cuts the padding, the cutting edge 223 pushes a portion of the padding laterally to the side of the cutting portion 220. In alternative embodiments, the cutting edge 223 may be asymmetrically arranged around the tip of the cutting edge; and / or the two halves of the cutting edge 223 may have a shape consisting of curves to change the distribution of the pressure applied by the cutting edge 223 to the padding.

[0205] In alternative embodiments, the cutting portion 220 can have a structure other than a blade. For example, in alternative embodiments, the cutting portion 220 can be configured as a wire, a knife, or other type of cutting device.

[0206] like Fig.14 and 24 As shown, the anvil portion 240 defines a substantially C-shaped track 241 and an orifice 244. The anvil portion 240 includes an anvil 242 and a backing surface 243. The backing surface 243 is substantially smooth to facilitate the sliding movement of the cutting portion 220 on the backing surface 243. As described above, the magnet 203 keeps the cutting portion 220 close to the backing surface 243.

[0207] As described above, a portion of the crank arm 204 of the crank 202 extends through the guide slot 231 of the shuttle 230. The adjacent end of the crank arm 204 extends into the track 241 of the anvil portion 240. The end of the crank arm 204 can move in the track 241 in a substantially C-shaped path. Fig.14 Track 241 can be seen in the video.

[0208] The aperture 244 in the anvil portion 240 is configured to receive a fastener that secures the anvil portion 240 to the frame 63 of the dunnage conversion machine 60, such as Figure 11-13 As described above, the anvil portion 240 remains fixed relative to the cutting portion 220 and the shuttle 230.

[0209] like Fig.14 and 15 As shown, the anvil 242 has a convex front end and substantially straight sides. The convex shape of the front end allows a portion of the padding pressed against the anvil 242 to gather on the convex front end, while the rest of the padding can be wrapped around the convex edge. This in turn facilitates a more even distribution of the pressure against the anvil 242 by pushing the padding to one side when, for example, the padding is cut by the opposite cutting edge (i.e., the cutting edge 223 of the cutting portion 220).

[0210] The curved convex profile of the front end of the anvil 242 distributes the pressure of the bundled material to the anvil portion 240 more smoothly. However, in other embodiments, the front end of the anvil 242 can have a different shape, such as a sharp tip, to provide an alternative pressure distribution for the pad. Similarly, the anvil portion 240 can have two or more front ends to provide an alternative pressure distribution for the pad.

[0211] Fig.17 The cutting portion 220 and the anvil portion 240 are depicted from above and in an assembled state. The backing surfaces 243 of the cutting portion 220 and the anvil portion 240 are flush with each other to help ensure that the pad material is cut cleanly in the cutting direction B when the cutting portion 220 is moved relative to the anvil portion 240 along the cutting plane. The cutting edge 223 is beveled (e.g. Fig.13 , 14 17 ) so that when the pad is cut, the pad is pushed away from the cutting portion 220. The bevel of the cutting edge 223 has a substantially straight or linear slope. In an alternative embodiment, the bevel of the cutting edge 223 can be composed of a curve. For example, the bevel can have a concave profile, that is, the bevel can be bent inwardly toward the anvil portion to help increase the sharpness of the cutting edge 223.

[0212] like Fig.14 and 15As shown in , the surface of the anvil 242 that contacts and limits the pad has a convex profile and is blunt, that is, the surface is not angled or beveled to form a sharp cutting edge. In an alternative embodiment, the surface of the anvil 242 can be configured with a sharp cutting edge to help cut the pad when the cutting portion 220 moves along the cutting direction B.

[0213] Figures 18 to 20 The assembled cutting mechanism 200 is depicted in use. In the assembled state, the cutting portion 220 and the anvil 242 define a window through which the underlayment can pass after being converted by the drive mechanism 300, as described below. Fig.18 The cutting mechanism 200 is depicted in a starting position. In the starting position, the cutting portion 220 is at its farthest distance from the anvil 242 and the window is at its largest size. In addition, the crank arm 204 of the crank 202 is located at a substantially midpoint of the guide slot 231. When in this central position, the crank arm 204 is aligned with the entry slot 234. This is the position of the crank arm 204 and the crank 202 at the beginning of the cutting cycle. In alternative embodiments, the crank arm 204 can be located at other positions within the guide slot 231 at the beginning of the cutting cycle.

[0214] Fig.19 The cutting mechanism 200 is depicted in an intermediate position. The crank arm 204 rotates approximately 90 degrees clockwise along the track 241 and translates toward one end of the guide slot 231. This movement of the crank arm 204 causes the crank arm 204 to move the shuttle 230 and the cutting portion 220 engaged therewith in the cutting direction B. The shuttle 230 is located between the side walls 215 of the cover 210 and is constrained and guided by the side walls 215 of the cover 210, as shown in FIG. Figure 18-24 As shown, this in turn causes the shuttle 230 to move linearly in the cutting direction B when the crank arm 204 rotates.

[0215] Since the cutting portion 220 is coupled to the shuttle 230 by the protrusion 233 , the cutting portion 220 moves with the shuttle 230 in the cutting direction B. In addition, when the cutting portion 220 slides against the backing surface 243 in the cutting direction B, the magnet 203 that magnetically couples the cutting portion 220 to the anvil portion 240 helps to keep the cutting portion 220 flush against the backing surface 243 of the anvil portion 220.

[0216] When the cutting mechanism 200 moves toward its intermediate position and passes through its intermediate position and the cutting portion 220 moves along the cutting direction B, the size of the window defined between the cutting portion 220 and the anvil 242 is reduced. More specifically, as the cutting edge 223 of the cutting portion 220 approaches the front end of the anvil 242, the size of the window is reduced. When the pad is located in the window, as during the normal operation of the pad conversion machine 60, when the cutting mechanism 200 is approximately in its intermediate position, the cutting edge 223 begins to cut the pad. The intermediate position is depicted as a position where the crank arm 204 rotates a quarter of a turn along the track 241 relative to the position of the crank arm 204 when the cutting mechanism 200 is in the starting position. However, in an alternative embodiment, the cutting mechanism 200 can be configured so that the "intermediate position" can be any position between the starting position of the cutting mechanism 200 and the end position of the cutting mechanism 200, as described below.

[0217] Fig. 20 The cutting mechanism 200 is depicted in its final position. In this position, the crank arm 204 has been rotated along the track 241 to a position opposite to the position of the crank arm 204 when the cutting mechanism 200 is in the initial position, that is, a position offset by about 180 degrees. Fig. 20 It can also be seen in FIG. 2 that, as the cutting portion 220 moves past the anvil 242, the window previously defined between the cutting portion 220 and the anvil 242 has been closed, i.e., no longer exists. Although not shown in the figure, when the cutting portion 220 advances along the cutting direction B to Fig. 20 In the position shown, the dunnage located in the window has been pushed toward the anvil 242 and cut by the cutting edge 223 of the cutting section 220. Thus, the dunnage portion that advanced through the window after the previous cutting cycle has been cut to form a separate dunnage piece. The newly cut dunnage piece then leaves the dunnage conversion machine 60 through the outlet chute 62.

[0218] When the cutting mechanism 200 reaches the end position, the crank arm 204 continues to rotate in the clockwise direction and eventually returns to the end position. Fig.18 As the crank arm 204 translates within the guide slot 231 and the track 241, the interaction of the crank arm 204, the shuttle 230 and the anvil portion 240 causes the cutting mechanism 200 to return to the Fig.18 As shown in the starting position. Fig.18 As shown, the shuttle 230 and cutting portion 220 have translated in a direction opposite to the cutting direction B, and the window between the cutting portion 220 and the anvil 242 has fully reopened and can receive an advancing flow of blanket material at the start of the next cutting cycle.

[0219] like Fig. 20As shown, when the cutting mechanism 200 is in the end position, the end of the shuttle 230 extends beyond the side wall 215 and the anvil portion 240. Alternative embodiments may be configured so that when the cutting mechanism 200 is in the end position, the end of the shuttle 230 does not extend beyond the anvil portion 240 or the side wall 215. For example, the length (i.e., lateral dimension) of the shuttle 230 may be reduced to ensure that the shuttle 230 remains within the confines between the side walls 215 to help reduce the space required to accommodate the dunnage conversion machine 60.

[0220] Figure 21 to Figure 24 The shuttle 230 is depicted detached from the rest of the cutting mechanism 200, the cutting portion 220 attached, and the magnet 203. Specifically, Fig.21 and 22 The shuttle 230, cutting portion 220, and magnet 203 are depicted disengaged when the cutting mechanism 200 is in a starting position. Fig.23 and Fig.24 The shuttle 230, cutting portion 220 and magnet 203 are depicted disengaged when the cutting mechanism 200 is in the end position.

[0221] Whether in the starting position or the end position, the shuttle 230 can only be disengaged when the crank arm 204 is aligned with the entry slot 234 in the shuttle 230. When the crank arm 204 is in any other position, that is, when the cutting mechanism 200 is in an intermediate position between the starting position and the end position, the crank arm 204 is located in a position within the guide slot 231 that is not aligned with the entry slot 234. The interference created between the crank arm 204 and the periphery of the guide slot 231 prevents the shuttle 230 from being disengaged from the rest of the cutting mechanism 200. This feature can help ensure that when a user attempts to remove the shuttle 230, the cutting mechanism 200 is not in the process of cutting the mat material, thereby enhancing the safety of the user.

[0222] like Figure 21-24 As shown, the shuttle 230 is disengaged from the rest of the cutting mechanism 200 by moving the shuttle 230 in the cutting direction B so that the crank arm 204 passes through the entry slot 234. The disengagement path is linear because the shuttle 230 is constrained to linear movement by the sidewalls 215. In an alternative embodiment, when the shuttle 230 is not constrained to linear movement, the shuttle 230 can be disengaged by moving the shuttle 230 along a non-linear disengagement path. The non-linear disengagement path can reduce the likelihood that the shuttle 230 will be accidentally removed or pushed out of position during normal dunnage production operation of the dunnage conversion machine 60 because disengagement of the shuttle 230 in such a case requires that the shuttle 230 follow a disengagement path that it would not follow during normal operation.

[0223] The disengagement path of shuttle 230 is along the cutting plane because magnet 203 holds cutting portion 220 and extends to keep shuttle 230 flush with anvil portion 240. In alternative embodiments, the disengagement path can be transverse to the cutting plane. For example, in an embodiment where cutting motor assembly 201 can be disengaged from cutting mechanism 200, shuttle 230 can be lifted from anvil portion 240 when disengaged to disengage shuttle 230 from cutting mechanism 200.

[0224] In the cutting mechanism 200, the shuttle 230 is disengaged by moving the shuttle 230 in the cutting direction B. This feature can reduce the possibility of injury to the user if the user loses their grip on the shuttle 230 during the disengagement process because the user's hand will move away from, rather than toward, the cutting edge 223 of the cutting portion 220. In an alternative embodiment, the shuttle 230 can be disengaged from the cutting mechanism 200 by being deflected away from the sidewall 215 (i.e., moved outward) and then lifted.

[0225] Figure 25 to Figure 28 Depicted Figure 7 3. The rollers 310, 320 of the drive assembly 300 are shown in FIG. The rollers 310, 320 are configured to compress the raw material 19 entering the dunnage conversion machine 60 to convert the raw material 19 into the dunnage 15, and to convey the dunnage 15 through and out of the dunnage conversion machine 60.

[0226] like Fig.25 As shown, the roller 310 has an outer surface 311 and defines a channel 312. The channel 312 is configured to receive the spindle 66 (such as Figure 7 310 is shown in the figure), so that the roller 310 can rotate around the main shaft 66. The roller 310 is in an idle state, that is, the roller 310 is not driven by the motor. The roller 310 is driven to rotate via the outer surface 311 and the rotating roller 320. In an alternative embodiment, the roller 310 can be driven by the motor of the drive assembly 300.

[0227] The outer surface 311 of the roller 310 is substantially smooth and made of a substantially non-stick material. For example, the surface 311 may be made of silicone. In alternative embodiments, the outer surface 311 of the roller 310 may be non-smooth.

[0228] The outer surface of roller 320 has a different shape or profile than roller 310. Roller 320 defines a channel 322, such as Fig.26 The channel 322 is used to accommodate the driving components (not shown) of the feed motor 301 so that the feed motor 301 can drive the roller 320 to rotate. In an alternative embodiment, the roller 320 can be idle and can be driven by the roller 310.

[0229] Roller 320 includes an outer surface 323. Outer surface 323 defines a plurality of circumferentially extending grooves 321. Grooves 321 are arranged side by side along the length or height of roller 320; and each groove 321 is symmetrically arranged around the longitudinal axis of roller 320. The lower end or inner end of each groove 321 is defined by the surface of roller 320. Fig.28 When viewed from an angle, the surface is substantially perpendicular to the longitudinal axis of the roller 320. Each groove 321 is configured to receive a corresponding annular ridge 325 of the roller 320, such as Fig.28 shown. Fig. 27 One of the ridges 325 is depicted individually.

[0230] The ridge 325 may be an O-ring formed of a pliable material. The ridge 325 acts as a non-planar contact surface that presses against the outer surface 311 of the roller 310, such as Fig.28 Each ridge 325 has a substantially circular cross-section and is sized to extend beyond the outer surface 323 of the roller 320. Fig.28 As shown, the ridges 325 extend substantially the same distance beyond the outer surface 323. Thus, the ridges 325 form protrusions, peaks, and valleys on the outer surface of the roller 320.

[0231] In alternative embodiments, the ridge 325 and the remainder of the roller 320 may be integrally formed. For example, the protrusions and the peaks and valleys defined by the ridge 325 may be formed on a one-piece embodiment of the roller 320.

[0232] During operation of the dunnage conversion machine 60, the raw material 19 is pulled from the supply station 13 through the feed port 100 between the rollers 310, 320. The ridges 325 and the opposing outer surfaces 311 of the rollers 310 apply pressure to the raw material 19, and the pressure distribution varies along the width or cross-direction of the raw material 19. The pressure causes the raw material 19 to wrinkle or deform, thereby converting the raw material 19 into dunnage.

[0233] Ridge 325 includes a leading end from surface 323 that is substantially perpendicular to surface 323. In alternative embodiments, ridge 325 may have a leading end at a different angle from surface 323 to provide an alternative pressure distribution to roller 310. For example, ridge 325 may be formed with a leading end at an angle between 0-45° to the surface of roller 320.

[0234] In alternative embodiments, the ridges 325 may have shapes other than annular, and / or may have non-circular cross-sections to produce a pressure distribution different from that produced by the ridges 325, which in turn may change the shape of the dunnage produced by the dunnage conversion machine 60. For example, an alternative embodiment of the ridges 325 may have one or more planar surfaces that define an outward curvature.

[0235] Furthermore, in alternative embodiments, the ridges 325 and grooves 321 may be configured such that the ridges 325 extend different distances beyond the outer surface 323 of the roller 320 to further vary the pressure distribution generated by the ridges 325 and the outer surface 311 of the roller 310. Furthermore, alternative embodiments of the roller 320 may be configured such that the grooves 321 extend in an inclined plane, i.e., not perpendicular to the longitudinal axis of the roller 320. Furthermore, one or more grooves 321 may have an orientation that is different than the orientation of other grooves 321.

[0236] Alternative embodiments of the system 10 may be equipped with a dunnage conversion machine 60 that includes conventional rollers, or with an apparatus that converts the stock material 19 into dunnage 15 using hardware other than rollers, such as a paper crumpler.

[0237] Those of ordinary skill in the art will appreciate that there are many types and sizes of dunnage that need or are desired to be produced, accumulated, and / or discharged, and that alternative embodiments of system 10 may be configured to produce such dunnage.

[0238] As used herein, the terms "top", "bottom" and / or other terms indicating direction are for convenience and are used to describe the relative position and / or direction between the various parts of the embodiment. It should be understood that certain embodiments or parts thereof may also be oriented in other positions. In addition, the term "about" should generally be understood to refer to corresponding numbers and numerical ranges. In addition, all numerical ranges herein should be understood to include each integer within the range.

[0239] Although certain features, functions, components and parts have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the present disclosure that reasonably fall within the permitted scope of equivalents. In addition, although illustrative embodiments of the disclosed technology are disclosed herein, it should be understood that many modifications and other embodiments may be designed by those skilled in the art. For example, the features of the various embodiments may be used in other embodiments, and the appended claims are intended to cover all such modifications and embodiments that fall within the spirit and scope of the disclosed technology. For example, the feed port 100 and its alternative embodiments may be used in conjunction with a padding machine other than the padding conversion machine 60. Similarly, the cutting mechanism 200 and its alternative embodiments may be incorporated into a padding conversion machine that does not include the drive assembly 300. Similarly, the drive assembly 300 and its alternative embodiments may be incorporated into a padding conversion machine that does not include the cutting assembly 200.

[0240] Conditional language, such as "may," "can," "might," or "could," unless expressly stated otherwise or otherwise understood in the context in which it is used, is generally intended to convey that certain implementations may include certain features, components, and / or operations, while other implementations do not. Thus, such conditional language is generally not intended to imply that features, components, and / or methods are in any way essential to one or more implementations, or that such features, components, and / or methods are included or will be performed in any particular implementation.

[0241] Many modifications and other embodiments of the disclosure set forth herein will become apparent with the aid of the teachings presented in the foregoing description and the associated drawings. Therefore, it should be understood that the disclosure is not limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. A dunnage conversion machine comprising: a drive mechanism configured to deform the raw material into the padding material; as well as A cutting mechanism comprising: an anvil having a surface consisting of a curve; and Cutting part; The anvil and the cutting portion are configured to cut the pad.

2. The dunnage conversion machine of claim 1, wherein the drive mechanism comprises one or more rollers.

3. The dunnage conversion machine of claim 1, wherein the cutting portion comprises a blade.

4. The dunnage conversion machine of claim 1, wherein the surface of the anvil comprised of the curve is convex.

5. The dunnage conversion machine of claim 4, wherein at least one of the anvil and the cutting portion is configured to move relative to the other of the anvil and the cutting portion to cut the dunnage.

6. The dunnage conversion machine of claim 5, wherein the anvil is stationary and the cutting portion is configured to move relative to the anvil to cut the dunnage.

7. The dunnage conversion machine of claim 5, wherein the anvil is configured such that dunnage material is urged around the convex surface as the cutting portion or anvil moves to cut the dunnage.

8. The dunnage conversion machine of claim 7, wherein the anvil has an opening defined therein and is configured to allow dunnage to pass through the anvil; and the opening is at least partially defined by the convex surface.

9. The pad material conversion machine of claim 5, wherein the anvil further comprises first and second side surfaces; the opening is further defined by the first and second side surfaces; and the anvil is further configured such that when the cutting portion of the anvil moves to cut the pad material, the pad material is pushed toward the first and second side surfaces.

10. The dunnage conversion machine of claim 1, wherein the curved surface of the anvil includes a sharp edge configured to cut the dunnage.

11. The dunnage conversion machine of claim 2, wherein the blade includes a tip configured to cut the dunnage.

12. The dunnage conversion machine of claim 2, wherein the blade includes a beveled leading edge.

13. The padding apparatus of claim 2, wherein the blade includes a leading edge having a convex shape.

14. The dunnage conversion machine of claim 13, wherein the leading edge is configured to push the dunnage toward a side of the cutting portion when the blade cuts the dunnage.

15. The dunnage conversion machine of claim 13, wherein the leading edge is substantially straight.

16. The dunnage conversion machine of claim 5, wherein the anvil includes a tip, the tip of the anvil and the tip of the cutting portion being configured to approach one another when the anvil and / or the cutting mechanism moves relative to the other of the anvil and the cutting mechanism.

17. A dunnage conversion machine comprising: a drive mechanism configured to deform the raw material into a padding material; as well as a cutting mechanism including a shuttle and a cutting portion; The cutting portion is configured to cooperate with the shuttle so that movement of the shuttle moves the cutting portion to cut the blanket.

18. The dunnage conversion machine of claim 17, wherein the drive mechanism comprises one or more rollers.

19. The dunnage conversion machine of claim 17, wherein the cutting portion comprises a blade.

20. The dunnage conversion machine of claim 17, wherein: The shuttle includes a protrusion having a base and wings extending laterally from the base; and The cutting portion is configured to receive the protrusion.

21. The dunnage conversion machine of claim 17, wherein the dunnage is fed to the cutting mechanism in a first direction, and the shuttle and the cutting portion are configured to move relative to the dunnage in a second direction substantially perpendicular to the first direction.

22. The dunnage conversion machine of claim 21, wherein one of the shuttle and the cutting mechanism includes a protrusion and the other of the shuttle and the cutting mechanism is configured to receive the protrusion.

23. The dunnage conversion machine of claim 22, wherein the protrusion is configured to engage the other of the shuttle and the cutting portion, and engagement of the protrusion with the other of the shuttle and the cutting portion couples the shuttle to the cutting portion for movement in the second direction.

24. The dunnage conversion machine of claim 22, wherein the other of the shuttle and the cutting portion has one or more openings formed therein; and the one or more openings are configured to receive the protrusions.

25. The dunnage conversion machine of claim 24, wherein the one or more openings have shapes and sizes that are substantially the same as corresponding shapes and sizes of the protrusions.

26. The dunnage conversion machine of claim 22, wherein the protrusion is substantially T-shaped.

27. The dunnage conversion machine of claim 22, wherein the protrusion includes a base and wings extending laterally from the base.

28. The dunnage conversion machine of claim 27, wherein: Movement of the cutting portion relative to the shuttle in a first direction is limited by the base; and Movement of the cutting portion relative to the shuttle in a second direction perpendicular to the first direction is limited by the wings.

29. The dunnage conversion machine of claim 22, wherein: The shuttle is configured to move the cutting portion along a cutting plane to cut the dunnage; and The protrusions are positioned in a plane that is substantially parallel to the cutting plane.

30. The dunnage conversion machine of claim 22, wherein the protrusion is integrally formed with the remainder of the shuttle.

31. A dunnage conversion machine comprising: a drive mechanism configured to deform the raw material into the padding material; as well as A cutting mechanism comprising: Cutting part; a shuttle configured to move the cutting portion along a plane to cut the dunnage; and a motor assembly including a rotatable crank configured to be coupled to the shuttle such that rotation of the crank moves the shuttle along a plane; Wherein the shuttle is configured to be disengaged from the crank by moving the shuttle along a plane when the crank is in a first angular position relative to the shuttle.

32. The dunnage conversion machine of claim 31 , wherein the drive mechanism comprises one or more rollers.

33. The dunnage conversion machine of claim 31, wherein the cutting portion comprises a blade.

34. The dunnage conversion machine of claim 31 , wherein the shuttle is configured to move the cutting portion along the plane to cut the dunnage when the crank moves from a first angular position of the crank to a second angular position of the crank.

35. The dunnage conversion machine of claim 34, wherein the second angular position is offset from the first angular position by approximately 180 degrees.

36. The dunnage conversion machine of claim 31, wherein: The shuttle is configured to move the cutting portion along the plane in a first direction; The shuttle defines a track having a longitudinal axis oriented in a second direction substantially perpendicular to the first direction; and The crank is configured to engage the shuttle via the track.

37. The dunnage conversion machine of claim 36, wherein: The shuttle also defines an opening adjacent to the track; The crank includes a protrusion; The track is configured to receive the protrusion; and The shuttle is also configured to disengage from the crank when the protrusion is aligned with the opening.

38. The dunnage conversion machine of claim 37, wherein the shuttle is further configured to disengage from the crank only when the protrusion is aligned with the opening.

39. The dunnage conversion machine of claim 37, wherein the shuttle is further configured such that the protrusion is aligned with the opening only when the crank is in the first or second angular position.

40. The dunnage conversion machine of claim 31, wherein: The shuttle is configured to move the cutting portion along the plane in a first direction; and The shuttle is also configured to disengage from the crank by moving the shuttle along the plane in a direction opposite to the first direction.

41. A dunnage conversion machine comprising: a drive mechanism configured to transform the raw material into the padding material; as well as A cutting mechanism comprising: Anvil; Cutting parts; and A magnet is mounted on one of the cutting portion and the anvil and is configured to magnetically and slidably couple the cutting portion and the anvil.

42. The dunnage conversion machine of claim 41, wherein the drive mechanism comprises one or more rollers.

43. The dunnage conversion machine of claim 41, wherein the cutting portion comprises a blade.

44. The dunnage conversion machine of claim 41, wherein the cutting portion or the anvil defines a recess configured to receive the magnet.

45. The dunnage conversion machine of claim 41, wherein the cutting portion further comprises a first edge, and wherein the magnet is mounted on the cutting portion adjacent the first edge.

46. ​​The dunnage conversion machine of claim 45, wherein: The magnet is a first magnet; The cutting portion also includes a second magnet and a second edge; A second magnet is mounted adjacent the second edge.

47. The dunnage conversion machine of claim 46, wherein the first edge defines a first side of the cut portion and the second edge defines a second side of the cut portion.

48. A system for producing litter, comprising: a dunnage conversion machine configured to transform raw material into dunnage; as well as A feedwell comprising an inlet chute configured to feed a strand of high density material to a dunnage conversion machine, wherein: The inlet chute includes a first wall having a first surface and a second wall having a second surface, the first surface and the second surface defining an interior passage; The internal passage is configured to form a portion of a material path for raw material along which the high density material is fed to the dunnage conversion machine; The second surface is configured to form a protrusion extending toward the first surface; and The projection and opposing portions of the first surface define a restriction within the interior passageway.

49. The system of claim 48, wherein the dunnage conversion machine comprises one or more rollers.

50. The system of claim 48, wherein: The restriction is configured to allow high density material to move past the restriction; and The restriction is also configured to prevent objects having a size exceeding a predetermined value from moving past the restriction.

51. The system of claim 48, wherein: The restriction is configured to allow high density material to move past the restriction; and The restriction is also configured to prevent a user's fingers and / or hand from moving past the restriction.

52. The system of claim 48, wherein the first surface is substantially planar.

53. The system of claim 48, wherein the first surface is flat.

54. The system of claim 48, wherein the first surface has a larger radius.

55. The system of claim 48, wherein the first surface has a radius of curvature greater than about 10 feet.

56. The system of claim 48, wherein the first surface is substantially horizontal.

57. The system of claim 48, wherein the first surface is substantially planar along the entire length of the first wall.

58. The system of claim 48, wherein the first wall is a bottom wall of the inlet chute and the second wall is a top wall of the inlet chute.

59. The system of claim 48, wherein: The inlet chute includes an inlet end and an outlet end; and The restriction is located closer to the inlet end than to the outlet end.

60. The system of claim 59, wherein: The inlet chute has a first width at the second position; The inlet chute has a second width at the outlet end; and The first width is greater than the second width.

61. The system of claim 48, wherein: the second wall is inclined at a first angle relative to the material path upstream of the second location; The second wall is inclined at a second angle relative to the material path downstream of the second location; and The first angle is steeper than the second angle.

62. A system for producing litter, comprising: a dunnage conversion machine configured to transform raw material into dunnage; as well as A feed inlet, comprising: an inlet chute configured to supply raw material to the dunnage conversion machine; as well as A guide is configured to guide the raw material to the inlet chute, the guide defining an aperture configured to receive the raw material.

63. The system of claim 62, wherein the dunnage conversion machine comprises one or more rollers.

64. The system of claim 62, wherein the guide comprises a first guide surface configured to guide the raw material in the first configuration to the inlet chute and to the orifice.

65. The system of claim 64, wherein the first guide surface is a leading edge of the guide.

66. The system of claim 64, wherein the first guide surface has a substantially arcuate shape.

67. The system of claim 64, wherein the first guide surface defines a single arc along a width of the first guide surface.

68. The system of claim 64, wherein the first guide surface defines a plurality of arcs along a width of the first guide surface.

69. The system of claim 64, wherein a width of the first guide surface is approximately equal to a width of the stock material when the stock material is in a substantially planar configuration.

70. The system of claim 64, wherein the guide comprises a textured and / or discontinuous surface on a portion of the guide adjacent to and below the first guide surface.

71. The system of claim 64, wherein the guide comprises a second guide surface configured to guide the raw material to the inlet chute when the raw material is in the twisted configuration.

72. The system of claim 71, wherein the second guide surface is located between the inlet chute and the first guide surface.

73. The system of claim 71 , wherein the orifice is defined in part by the second guide surface.

74. The system of claim 62, wherein the orifice is configured to receive the raw material when the raw material is in a distorted configuration.

75. The system of claim 71 , wherein the second guide surface is substantially linear.

76. The system of claim 71, wherein: an aperture extending through an upper surface of the guide; and The second guide surface is substantially perpendicular to the first guide surface.

77. The system of claim 71, wherein the second surface is configured to bend the stock material approximately 90 degrees.

78. The system of claim 62, wherein the inlet chute defines an inlet opening for receiving the high density material, and the width of the inlet opening is greater than the width of the orifice.

79. A dunnage conversion machine comprising a drive mechanism, wherein the drive mechanism comprises: a first roller including an outer surface having a first shape; as well as a second roller including an outer surface having a second shape different from the first shape; The first roller and the second roller are configured to convert the high density raw material into the low density padding material.

80. The dunnage conversion machine of claim 79, wherein the outer surface of the first roller is substantially smooth.

81. The dunnage material conversion machine of claim 79, wherein the outer surface of the second roller defines a protrusion configured to press the stock material against the outer surface of the first roller.

82. The dunnage conversion machine of claim 81, wherein the protrusion comprises a substantially planar surface configured to press the stock material against the outer surface of the first roller.

83. The dunnage conversion machine of claim 81, wherein the protrusion includes a pointed tip configured to press the stock material against the outer surface of the first roller.

84. The dunnage conversion machine of claim 79, wherein the outer surface of the second roller includes a plurality of grooves, and the second roller includes a plurality of ridges disposed in the grooves.

85. The dunnage conversion machine of claim 79, wherein an outer surface of the first roller comprises a substantially non-stick material.

86. The dunnage conversion machine of claim 85, wherein the non-stick material comprises silicone.

87. The dunnage conversion machine of claim 79, wherein the first roller is idle.

88. The dunnage conversion machine of claim 87, wherein the drive mechanism further comprises a motor configured to rotate the second roller during operation.

89. The dunnage conversion machine of claim 84, wherein each ridge comprises an o-ring.

90. The dunnage conversion machine of claim 84, wherein a first ridge of the plurality of ridges extends a first distance from the second roller; and a second ridge of the plurality of ridges extends a second distance from the second roller that is different than the first distance.

91. The dunnage conversion machine of claim 90, wherein the first ridge is configured to press the stock material against the first roller with a first pressure; and the second ridge is configured to press the stock material against the first roller with a second pressure different from the first pressure.

92. The dunnage conversion machine of claim 91, wherein the second pressure is approximately zero.

93. The dunnage conversion machine of claim 91 wherein the plurality of ridges includes a third ridge extending from the second roller a third distance different than the second distance; and The second ridge is positioned between the first ridge and the third ridge.

94. The dunnage conversion machine of claim 81, wherein the protrusion extends in a plane that is not perpendicular to the longitudinal axis of the second roller.

95. A system for producing litter, comprising: a dunnage conversion machine configured to transform raw material into dunnage; as well as a feed opening including an inlet chute configured to direct raw material to a dunnage conversion machine; wherein: The inlet chute includes a first lower inner surface, an inclined surface adjacent to and upstream of the first lower inner surface; a second lower inner surface adjacent to and upstream of the inclined surface; a first upper inner surface; and a second upper inner surface adjacent to and upstream of the first upper inner surface; The first lower interior surface, the inclined surface, the second lower interior surface, the first upper interior surface, and the second upper interior surface define a passage extending between an inlet end and an outlet end of the chute; A portion of the channel defined between the first lower inner surface, the inclined surface, and the first upper inner surface is configured to gather raw material; and A portion of the passage defined between the second upper interior surface and the second lower interior surface is configured to direct the gathered raw material to a location at the outlet end of the chute.

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