Dunnage converter and dunnage conversion system

Abstract

The dunnage converter includes a drive mechanism configured to deform raw materials 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 converter may also include a cutting mechanism including an anvil having a curved surface and a cutting portion, and the anvil and the cutting portion are configured to cut the dunnage. The dunnage converter may also include an inlet chute configured to supply raw materials to the dunnage converter. The inlet chute may include a protrusion disposed within an internal channel of the inlet chute and configured to restrict large objects such as an operator's finger or hand from falling into and moving within the internal channel.

Description

Technical Field

[0001] The present disclosure relates to a system for converting paper raw materials and other materials into dunnage for use as packaging materials.

Background Art

[0002] Paper-based protective packaging, or dunnage, is manufactured by crumpling or deforming paper raw materials. More specifically, paper dunnage is generally manufactured by passing a continuous sheet of paper through a dunnage converter. The continuous sheet of paper can be provided, for example, from a paper roll or a folded stack of paper. The dunnage converter uses, for example, opposing rollers through which the raw material passes to convert the raw material into a lower density dunnage material. The rollers grip and pull the raw material from the roll or stack and deform the raw material as it passes between the rollers. The resulting dunnage can be cut to the required length to effectively fill the voids within the container that houses the product. The dunnage material can be manufactured as needed for individuals or machines performing packaging operations.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The function of smoothly and continuously supplying paper from a stack or roll is important for the proper and efficient operation of the dunnage converter. If the flow of paper supplied to the dunnage converter becomes clogged or otherwise interrupted, the machine may not be able to produce dunnage at the required speed, and the supply of dunnage may cause delays in subsequent packaging and shipping operations that require it. Also, if it clogs frequently, the dunnage converter may be damaged and maintenance costs may increase.

[0004] The function of being able to cleanly and repeatedly cut the dunnage is also important for the proper and efficient operation of the dunnage converter. For example, the cutting blade needs to be replaced regularly to maintain a sharpness sufficient to cut the newly formed dunnage into individual pieces. Therefore, the function of being able to quickly and safely replace the cutting blade of the dunnage converter is a desirable characteristic.

[0005] Also, the final shape of the dunnage is determined by rollers that crumple or deform the paper raw material. It is desirable for the rollers to deform the paper raw material to significantly increase the overall volume occupied by the converted paper raw material, i.e., the dunnage, so that the dunnage can fulfill its original purpose of volume filling and buffering.

Means for Solving the Problem

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

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

[0012] In another aspect of the disclosed technology, the anvil is configured such that when the cutting portion or the anvil moves to cut the dunnage, the dunnage material is pushed into the surrounding of the convex surface.

[0013] In another aspect of the disclosed technology, the anvil has an opening defined therein and configured such that the dunnage can 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 includes 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 dunnage, the dunnage material is extruded towards 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 dunnage.

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

[0017] In another aspect of the disclosed technology, the blade includes an inclined tip.

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

[0019] In another aspect of the disclosed technology, the tip is configured to extrude the dunnage towards the side surface of the cutting portion when the blade cuts the dunnage.

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

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

[0022] In another aspect of the disclosed technology, the dunnage converter includes a drive mechanism configured to deform raw materials into dunnage, and a cutting mechanism having a shuttle and a cutting part. The cutting part is configured to mesh with the shuttle, and the movement of the shuttle causes the cutting part to move and 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 part includes a blade.

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

[0026] In another aspect of the disclosed technology, the dunnage is supplied to the cutting mechanism in a first direction, and the shuttle and the cutting part 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 part includes a protrusion, and the other of the shuttle and the cutting part is configured to receive the protrusion.

[0028] In another aspect of the disclosed technology, the protrusion is configured to engage with the other of the shuttle and the cutting part, and the engagement between the protrusion and the other of the shuttle and the cutting part causes the shuttle to be coupled to the cutting part and enables the shuttle to move in the second direction.

[0029] In another aspect of the disclosed technology, the other of the shuttle and the cutting part 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 dimensions of the one or more openings are substantially the same as those of the protrusions respectively.

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

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

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

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

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

[0037] In another aspect of the disclosed technology, the dunnage converter includes a drive mechanism configured to deform raw materials into dunnage and a cutting mechanism. The cutting mechanism includes a cutting portion and a shuttle configured to move the cutting portion along a plane to cut the dunnage, and a motor assembly coupled to the shuttle and including a rotatable crank configured such that the rotation of the crank causes the shuttle to move along the plane. The shuttle is configured to be disengaged from the crank by moving the shuttle along the plane when the crank is in a first angular position relative to the shuttle.

[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 dunnage when the crank moves from the first angular position to the second angular position.

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

[0042] In another aspect of the disclosed technology, 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.

[0043] In another aspect of the disclosed technology, the shuttle further defines an opening adjacent to 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 angular position or the 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 be disengaged 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, the dunnage converter includes a drive mechanism configured to deform raw materials into dunnage and a cutting mechanism. The cutting mechanism includes an anvil, a cutting portion, and a magnet attached to one of the cutting portion and the anvil and 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 the 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 attached to 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 attached adjacent to the second edge.

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

[0054] In another aspect of the disclosed technology, a dunnage manufacturing system includes a dunnage converter configured to transform raw materials into dunnage, and an inlet including an inlet chute configured to supply a line of high-density material to the dunnage converter. 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 channel.

[0055] The internal channel is configured to form part of the material path of the raw material through which the high-density material is supplied to the dunnage converter. The second surface is configured to form a protrusion extending toward the first surface. The protrusion and a part of the opposite side of the first surface define a restriction within the internal channel.

[0056] In another aspect of the disclosed technology, the dunnage converter includes one or more rollers.

[0057] In another aspect of the disclosed technology, the restriction is configured to permit the high-density material to move beyond the restriction, and the restriction is further configured to prevent an object having dimensions exceeding a predetermined value from moving beyond the restriction.

[0058] In another aspect of the disclosed technology, the restriction is configured to permit the high-density material to move beyond the restriction, and the restriction is further configured to prevent a user's finger and / or hand from moving beyond 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 flat.

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

[0062] In another aspect of the disclosed technology, the first surface has a radius of curvature greater than about 10 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 the lower wall of the inlet chute and the second wall is the upper 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 the outlet end.

[0067] In another aspect of the disclosed technology, the inlet chute has a first width at a second position, 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 with respect to the material path upstream of the second position, the second wall is inclined at a second angle with respect to the material path downstream of the second position, and the first angle is steeper than the second angle.

[0069] In another aspect of the disclosed technology, the dunnage manufacturing system includes a dunnage converter configured to deform raw material into dunnage and an inlet. The inlet includes an inlet chute configured to supply raw material to the dunnage converter and a guide configured to direct the raw material to the inlet chute. The guide defines an opening configured to receive the raw material.

[0070] In another aspect of the disclosed technology, the dunnage converter includes one or more rollers.

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

[0072] In another aspect of the disclosed technology, the first guide surface is the tip 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 the width of the first guide surface.

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

[0076] In another aspect of the disclosed technology, the width of the first guide surface is substantially 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 surface and / or a discontinuous surface on a portion of the guide adjacent 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 to the inlet chute when the raw material is in a twisted configuration.

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

[0080] In another aspect of the disclosed technology, the opening is partially defined by the second guide surface.

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

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

[0083] In another aspect of the disclosed technology, the opening extends through the 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 impart a bend of approximately 90 degrees to the raw material.

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

[0086] In another aspect of the disclosed technology, the dunnage converter includes a drive mechanism having a first roller with an outer surface having a first shape and a second roller with 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 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, the outer surface of the second roller defines protrusions configured to compress the raw material against the outer surface of the first roller.

[0089] In another aspect of the disclosed technology, the protrusions include a substantially flat 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 within the grooves.

[0092] In another aspect of the disclosed technology, the outer surface of the first roller includes 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 a non-operating 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 of the ridges includes an O-ring.

[0097] In another aspect of the disclosed technology, a first one of the plurality of ridges extends a first distance from the second roller, and a second one of the plurality of ridges extends a second distance from the second roller that is different from 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 at a first pressure, and the second ridge is configured to press the raw material against the first roller at a second pressure that is different from the first pressure.

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

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

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

[0102] In another aspect of the disclosed technology, a dunnage manufacturing system includes a dunnage converter configured to deform raw material into dunnage and an inlet including an inlet chute configured to direct the raw material to the dunnage converter. 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.

[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 that extends 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 collect the raw material. A portion of the channel defined between the second upper inner surface and the second lower inner surface is configured to direct the collected raw material to the location of the outlet end of the chute.

[0104] The following drawings illustrate specific embodiments of the present disclosure and, accordingly, do not limit the scope of the present disclosure. The drawings are not to scale and are intended to be used in conjunction with the description in the following detailed description. Embodiments of the present disclosure are described below in conjunction with the accompanying drawings, in which like numbers indicate like components.

Brief Description of the Drawings

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Best Mode for Carrying Out the Invention

[0106] In the following description, conventional features of the disclosed technology that are obvious to those skilled in the art will be omitted or described only briefly. References to various embodiments do not limit the scope of the claims appended to this specification. Also, none of the examples described in this specification are limiting, and are intended to merely describe some of the many possible embodiments of the appended claims. Further, the special features described in this specification can be used in combination with the other features described, in each of the various possible combinations and variations. Those skilled in the art will know how to use the present invention in combination with ordinary experimentation to achieve other results not specifically disclosed in the examples or embodiments.

[0107] Unless otherwise specifically defined herein, all terms are to be accorded the broadest possible interpretation, including any meanings that may be implied from the specification, as well as meanings understood by those skilled in the art and / or defined in dictionaries, treatises, etc. Unless otherwise specifically defined, all technical and scientific terms used herein shall have the same meaning as commonly understood by those skilled in the art in the field of the disclosed technology. Also, the singular forms "a", "an", and "the" as used in the specification and the appended claims shall include plural referents unless otherwise specified, and the terms "includes" and / or "including" as used herein are to identify the presence of the stated features, elements, and / or components, but are not to be construed as precluding the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Further, methods, devices, and materials similar or equivalent to those described herein may also be used in the practice or testing of the disclosed technology.

[0108] Various embodiments of the disclosed technology are provided throughout this disclosure. The use of these embodiments is for illustrative purposes only and is not intended to limit the scope and meaning of the invention or the exemplified forms. Similarly, the invention is not limited to the specific preferred embodiments described herein. Indeed, modifications and variations of the invention will be apparent to those skilled in the art upon reading this specification and can be made without departing from the spirit and scope of the invention. Accordingly, the invention is limited only by the terms of the claims and the full scope of equivalents to which the claims are entitled.

[0109] As used herein, the terms "substantially" and "substantially equal" indicate that the equal relationship is not a strict relationship and do not exclude functionally similar variations. Unless otherwise indicated in the context or description, when using the terms "substantially" or "substantially equal" in relation to two or more described dimensions, the equal relationship between the dimensions includes variations where the least significant digit of the dimension does not change even when using the accepted mathematical and industrial principles in the art (e.g., rounding, measurement, or other systematic errors, manufacturing tolerances, etc.). The term "substantially parallel" as used herein indicates that the parallel relationship is not a strict relationship and does not exclude functionally similar variations. The term "substantially orthogonal" as used herein indicates that the orthogonal relationship is not a strict relationship and does not exclude functionally similar variations.

[0110] A system for converting a high-density raw material into a low-density dunnage is disclosed. The raw material is processed by a longitudinal creasing machine that forms creases in the longitudinal direction of the raw material to form dunnage, or a transverse creasing machine that forms creases in the transverse direction across the raw material. The raw material supply unit can store the raw material in the form of a roll (drawn from the inside or outside of the roll), a take-up, a fan-folded source, or other suitable forms. The raw material may be continuous or perforated. The conversion device supplies the raw material from the supply unit in a first direction that may be the reverse run-out direction.

[0111] The raw material may be any suitable type of protective packaging material, including, for example, flat or rolled paper stock, other dunnage and void fill materials, inflatable packaging pillows, etc. In some embodiments, a supply of sheet-like other paper or fiber-based materials can be used. In other embodiments, a supply of wound fibrous materials such as ropes or threads can be used. In other embodiments, thermoplastic materials such as webs of plastic materials that can be used to form pillow packaging materials can be used. Examples of papers used include supply units folded into a fan shape containing raw materials with a width of 30 inches and / or a width of 15 inches. Preferably, these sheets are folded into a fan shape as a single layer. In other embodiments, multiple sheet layers can be folded into a fan shape, such that the dunnage is made from overlapping sheets that are crumpled together in the conversion process.

[0112] Suitable raw materials can be used. For example, the raw material can have a basis weight of from about 20 pounds to about 100 pounds. The raw material can include paper stock stored in a high-density configuration having a first longitudinal end and a second longitudinal end and later converted to a low-density configuration by a conversion system. The raw material can be a ribbon of sheet material stored in a folded continuous structure as shown in FIGS. 1 and 2, or a ribbon of sheet material stored in a coreless roll as shown in FIGS. 29 and 30. The raw material may be formed or stored as a single layer or multiple layers of material. When using a multi-layered material, the layers can include multiple layers. Other types of materials can also be used, such as pulp-based unused and recycled papers, newsprint, cellulose and starch compositions, and poly or synthetic materials, having suitable thicknesses, weights, and dimensions.

[0113] In some embodiments, the raw material supply unit may have a foldable continuous configuration. For example, a foldable material such as paper can be repeatedly folded to form a stack or a three-dimensional body. The term "three-dimensional body" has a non-negligible three-dimension as opposed to a "two-dimensional" material. A continuous sheet, such as a sheet of paper, plastic, or metal foil, may be folded with a plurality of folds extending laterally with respect to the longitudinal direction of the continuous sheet or laterally with respect to the supply direction of the sheet. For example, folding a continuous sheet having a substantially uniform width along a lateral fold can form or define sheet sections having substantially the same width. The continuous sheet can be sequentially folded in opposite or alternating directions to produce an accordion-shaped continuous sheet. For example, the folds can form or define sections along the continuous sheet, and the sections may be substantially rectangular.

[0114] For example, when the continuous sheet is sequentially folded, an accordion-shaped continuous sheet with sheet sections having substantially the same size and / or shape as each other may be produced. A plurality of adjacent sections defined by the folds may be generally rectangular and may have the same first dimension (e.g., a dimension corresponding to the width of the continuous sheet) and the same second dimension generally along the longitudinal direction of the continuous sheet. For example, when adjacent sections are in contact with each other, the continuous sheet may be configured as an accordion-shaped three-dimensional body or stack formed and compressed by the folds, and the continuous sheet may form a three-dimensional body or stack.

[0115] The folds of the raw material may have an appropriate orientation not only with respect to the longitudinal and lateral directions of the continuous sheet but also with respect to each other. Also, the raw material unit can have folds in lateral directions parallel to each other. For example, the sections formed by the folds can be compressed to form a three-dimensional body that is a rectangular parallelepiped. Further, the raw material can have one or more folds that are non-parallel to the lateral folds.

[0116] The raw materials can be provided as any suitable number of individual raw material units. In some embodiments, two or more raw material units can be connected to each other to continuously supply material to the dunnage converter. The material can be supplied sequentially or simultaneously from the connected raw material units, i.e., in series or in parallel. The raw material units can have various suitable sizes and configurations and can include one or more stacks or rolls of suitable sheet material. The term "sheet material" generally refers to a material that is sheet-like and two-dimensional. That is, two dimensions of the material are substantially larger than the third dimension, such that the third dimension is negligibly small or very small compared to the other two dimensions. Also, the sheet material can generally be flexible and foldable, such as the exemplary materials described herein.

[0117] The raw material units can include an attachment mechanism for connecting a plurality of raw material units, for example, to produce a continuous material supply from a plurality of individual raw material units. The respective ends and beginnings of successive rolls can be joined by adhesive or other suitable means, facilitating the formation of a continuous stream of sheet material that can be supplied to the dunnage converter by daisy-chain connecting the rolls.

[0118] When the continuous sheet is folded along the horizontal fold line, a generally rectangular sheet section can be formed or defined. The rectangular sheet sections can be stacked, for example, by alternately folding the continuous sheet, and a three-dimensional body having longitudinal, lateral, and vertical dimensions can be formed. The raw material from the raw material unit can be supplied through an inlet such as inlet 100 as shown in FIGS. 1-10. In some applications, the lateral direction of the continuous sheet of raw material may be larger than one or more dimensions of the inlet. For example, the lateral dimension of the continuous sheet may be larger than the diameter of a generally circular inlet. Narrowing the width of the continuous sheet in this way at the start of the conversion process facilitates the passage of the continuous sheet through the inlet. When the width of the leading portion of the continuous sheet is narrowed, smooth entry and / or transition of the daisy-chain connected continuous sheet is facilitated, and snags or tears in the continuous sheet may be reduced or eliminated. Also, narrowing the width of the continuous sheet at its starting portion facilitates connecting or daisy-chain connecting two or more raw material units. For example, the connection or daisy-chain connection of materials having a tapered section can be achieved using smaller connectors or splice elements than normal. Also, the tapered section is easier to manually align or connect compared to a full-width sheet section.

[0119] FIGS. 1 and 2 show an embodiment of a system for manufacturing dunnage 10. System 10 is configured to process raw material 19 into dunnage 15. System 10 includes a supply unit 18 for raw material 19 and a dunnage device 50.

[0120] Dunnage device 50 includes a dunnage converter 60, a support portion 12 configured to support dunnage converter 60, and a supply station 13 configured to hold supply unit 18 for raw material 19.

[0121] The specific configuration of the illustrated support portion 12 is disclosed for illustrative purposes only, and the support portion 12 can also have other configurations suitable for supporting the dunnage converter 60.

[0122] Similarly, the shelf or basket-type configuration of the supply station 13 shown in FIGS. 1 and 2 accommodates the supply unit 18 in the form of a stack of folded raw materials 19, which is disclosed for illustrative purposes only. The supply station 13 can also have other configurations suitable for supporting the supply unit 18, such as, for example, a single bundle, multiple daisy-chain bundles, a flat configuration, a roll configuration, and / or a curved configuration.

[0123] For example, FIGS. 29 and 30 show another embodiment of the system 10 as a system for manufacturing dunnage 10a. The system 10a includes a supply station 13a configured to accommodate a supply unit 18a of roll-shaped raw material 19. In another alternative embodiment, the supply station 13 can be a cart (not shown) movable relative to the dunnage converter 60. In other embodiments, the supply station 13 can be a basket (shown in FIGS. 1 and 2), a shelf, or another type of support structure attached to the stand 12. In such embodiments, the dunnage converter 60 and the supply station 13 do not move relative to each other. In other embodiments, the supply station 13 and the dunnage converter 60 may be fixed relative to each other or not attached to each other. In another alternative embodiment, the supply station 13 and the dunnage converter 60 may be configured to move relative to each other, either attached together or not attached together.

[0124] The supply station 13 can support one or more supply units 18 of the raw material 19. FIGS. 1A to 1C show the supply station 13 that supports a plurality of supply units 18. In the application where a plurality of supply units 18 are housed in the supply station 13, the end sheet and the start sheet of the adjacent supply units 18 are connected to each other before or after being placed in the supply station 13. By connecting a plurality of supply units to each other or in a daisy-chain connection, the raw material 19 can be continuously supplied.

[0125] As shown in FIGS. 1 and 2, the raw material 19 is converted into the dunnage 15 along the material path A through the system 10. The material path A has an inlet end where the raw material 19 is supplied to the system 10 and an outlet end where the dunnage 15 is discharged from the system 10.

[0126] FIGS. 3 to 8 show the dunnage converter 60 of the system 10. As shown in FIGS. 3 and 4, the dunnage converter 60 includes a housing 61, an inlet 100, an outlet chute 62, a cutting motor assembly 201, and a feed motor 301 extending from the housing 61.

[0127] For the sake of convenience of explanation, FIGS. 5 and 6 show the dunnage converter 60 without the housing 61, so that the frame 63 and the cutting mechanism 200 of the dunnage converter 60 are exposed. As shown in FIGS. 5 and 6, the inlet 100 is rotatably coupled to the frame 63 via the inlet spindle 65. Specifically, as shown in FIGS. 8 to 10, the inlet 100 defines a channel 131 that 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. FIG. 7 shows the inlet 100 rotating upward about the inlet spindle 65 from the closed position or the lowered position shown in FIGS. 1 to 6 to the raised position or the open position shown in FIG. 7. Since the inlet 100 can be rotated upward in this way, the user can remove materials that may clog or block the outlet portion of the inlet 100.

[0128] The dunnage converter 60 also includes the drive assembly 300 shown in FIG. 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 converter 60 and convert the raw material 19 into dunnage.

[0129] The dunnage converter 60 is configured to reverse the moving direction of the raw material 19 when the raw material 19 moves within the dunnage converter 60. By the function of reversing the moving direction of the raw material 19, the converted dunnage material discharged from the dunnage converter 60 can be drawn to a specific type of cutting device provided in the dunnage converter 60, thereby assisting the cutting mechanism in cutting the dunnage material.

[0130] Referring to FIGS. 8 to 10, the inlet 100 includes a guide 110, an inlet chute 120, and an outlet plate 130. The guide 110 is adjacent to the front, i.e., the upstream end, of the inlet chute 120. The guide 110 and the inlet chute 120 may be integrally formed. Alternatively, the guide 110 and the inlet chute 120 may be separately formed and connected by suitable means such as fasteners, and the guide 110 can be removably connected to the inlet chute 120. With a removable configuration, for example, when it is not necessary or desirable to bend the raw material 19 when the raw material 19 is supplied to the inlet chute 120, the guide 110 can be removed from the inlet chute 120. By making the guide 110 removable, the possibility that the user can customize the method of bending the raw material 19 when the raw material 19 is supplied to the inlet chute 120 is increased.

[0131] The outlet plate 130 is adjacent to the rear, i.e., the 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 separately formed and connected by suitable means.

[0132] The inlet chute 120 has an opening 121 that defines an inlet end 101 for receiving the raw material 19. The outlet plate 130 defines an outlet end 102 through which the raw material 19 passes when it exits the inlet 100 while moving along the material path A. The outlet plate 130 is configured to fix the inlet 100 to the frame 63. More specifically, the outlet plate 130 defines a channel 131 for receiving a spindle 65 that couples the inlet 100 to the frame 63.

[0133] The guide 110 is configured to receive the raw material 19 when the raw material 19 is supplied to the inlet chute 120 and passes through the inlet chute 120. The guide 110 extends from below the mouth 121 of the inlet chute 120, and the upper surface 112 of the guide 110 and the first lower surface 122 of the inlet chute 120 define a substantially planar surface for supplying the raw material 19 along the material path A. Therefore, 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. Also, when the raw material 19 moves on the upper surface 112 and the first lower surface 122 of the guide 110, it moves substantially horizontally and does not change its orientation.

[0134] As used herein, the term "substantially planar surface" can refer to a surface that appears to be completely flat and smooth. For example, a "substantially planar surface" can be a completely flat surface. Also, a "substantially planar surface" may, for example, be a surface having a large radius of curvature of 10 feet or more.

[0135] The guide 110 is shown 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, but in other embodiments, the guide 110 may extend at an angle 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 angled with respect 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 straight.

[0136] The guide 110 can extend at an upward or downward angle from the inlet chute 120. When the guide 110 extends at a downward angle from the inlet chute 120, the raw material supplied onto the guide 100 may be further conditioned by the bending between the first lower surface 122 of the inlet chute 120 and the upper surface 112 of the guide 110. This bending causes the raw material 19 to become more flexible for conversion into dunnage.

[0137] The guide 110 also has a first guide surface 113 shown in FIGS. 8-10. The first guide surface 113 is adjacent to the upper surface 112 of the guide 110 and forms the upstream end of the guide 110. Since the first guide surface 113 is substantially arc-shaped when viewed from above, the raw material 19 sent on the first guide surface 113 is bent around a plurality of axes to form a complex bend. This bending makes the raw material 19 more flexible for conversion into dunnage. In particular, when the sheet material 18 is folded and the raw material 19 supplied from the supply unit 18 where adjacent folds are stacked is supplied to the inlet 100 in a substantially planar form as shown in FIGS. 1 and 2 shown, it is useful when the raw material 19 is supplied to the inlet 100 in a substantially planar form.

[0138] The first guide surface 113 defines a single arc along its width, i.e., the dimension in the left-right direction. In another embodiment, the guide surface 113 is shaped to define a plurality of arcs, and the raw material 19 supplied onto the guide surface 113 is bent at a plurality of points on the raw material 19. Depending on the desired shape of the dunnage to be manufactured, this additional bending facilitates the conversion of the raw material 19 into a specific type of dunnage. For example, when the raw material is bent multiple times by the plurality of arcs of the guide surface 113, the raw material becomes easily crumpled or bent when converted into dunnage.

[0139] In yet another alternative embodiment, the guide surface 113 can have a non-arc shape. For example, the first guide surface 113 is shown as being substantially non-angular as a means of avoiding breakage of the raw material, but in other embodiments, the first guide surface 113 may be more angular. Such an angular shape serves to form a bend in a specific type of thicker raw material 19 that would not be bent by the non-angular first guide surface 113. In yet another alternative embodiment, the first guide surface 113 can be configured with a sharp tip to form a more distinct bend when the raw material 19 is sent over the first guide surface 113.

[0140] The first guide surface 113 can have a width substantially the same as the width of the raw material 19 before the raw material 19 is deformed by the dunnage converter 60, that is, the left - right dimension. Due to this characteristic of the first guide surface 113, the guide 110 can always continue to be in contact with the raw material 19, and as a result, the raw material 19 can be more accurately guided into the inlet chute 120. In another embodiment where precise guidance is not required, the first guide surface 113 can have a width different from the width of the raw material 19.

[0141] The guide 110 has a textured or discontinuous surface 114 on a part of the guide 110 that is adjacent to and located below the first guide surface 113. As shown in FIGS. 8 - 10, the discontinuity of the surface 114 is defined by recesses or depressions that extend from the surface 114 into the inside of the guide 110. Due to this discontinuity of the surface 114, the friction between the surface 114 and the user's hand increases, which helps the user to grip the guide 110 more firmly.

[0142] The guide 110 defines an opening 111 as shown in FIG. 8. The opening 111 penetrates the upper surface 112 and is configured such that the raw material 19 can pass through when the raw material 19 is supplied to the dunnage converter 60. The guide 110 also includes a second guide surface 115, which is also shown in FIG. 8. After passing through the opening 111, the raw material 19 moves on 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 shows the twisted - configured raw material 19 passing over the second guide surface 115 when it is supplied upward from the supply unit 18 in the form of a roll of the raw material 19 through the opening 111.

[0143] The second guide surface 115 is shaped such that when the raw material 19 is fed over the second guide surface 115, the raw material 19 becomes more flexible. As shown in FIG. 8, the second guide surface 115 has an acute angle, i.e., a bend of 90 degrees, so that the raw material 19 normally passes over the second guide surface 115 in a non-planar configuration. Therefore, a relatively sharp surface is required to bend the raw material 19 and make it more flexible for conversion into dunnage. In another embodiment, the second guide surface 115 can be made smooth so that a thinner raw material can move over the second guide surface without being bent.

[0144] The second guide surface 115 is configured to accommodate a raw material 19 having a width, or left and right dimensions, that is narrower than the width of the raw material 19 that can be supplied to the dunnage converter 60 via the first guide surface 113. Therefore, the second guide surface 115 requires a narrower width than the first guide surface 113 to maintain a constant contact with the raw material 19. Accordingly, the second guide surface 115 has a width, or left and right dimensions, that is narrower than the width of the first guide surface 113.

[0145] The second guide surface 115 is substantially linear to reduce the possibility that the non-planar raw material 19 fed over the second guide surface 115 catches on the edge of the second guide surface 115 and tears. In another embodiment, the second guide surface may be non-linear. For example, the second guide surface 115 may have an arcuate profile similar to the first guide surface 113 so that the raw material 19 can bend easily as it passes over the second guide surface 115. In other embodiments, the second guide surface 115 is arcuate in the opposite direction to the first guide surface and can maintain the raw material 19 well at a desired position such as the center line of the inlet 100.

[0146] The guide 110 is illustrated as having one opening 111. In another embodiment, the guide 110 can include a plurality of openings 111. For example, in an application where a plurality of streams of raw material 19 are supplied to the inlet chute 120, each opening 111 can accommodate one of the respective streams.

[0147] Referring to FIG. 10, the inlet chute 120 further includes an upper wall 123 and a lower wall 124. The upper 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.

[0148] The lower 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.

[0149] Continuing to 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 channel 132 within the inlet chute 120. The channel 132 receives the raw material 19 and guides the raw material 19 moving between the inlet end 101 and the outlet end 102 of the inlet chute 120.

[0150] The first lower inner surface 122 is substantially planar and substantially smooth. This feature can reduce or eliminate the possibility that the raw material 19 gets clogged or caught when the raw material 19 is supplied through the inlet chute 120. The inclined surface 128 is substantially planar and provides a smooth transition between the first lower inner surface 122 and the second lower inner surface 141. In another embodiment, the inclined surface 128 has a curved profile and can provide a smoother transition from the inclined surface 128 to the second lower inner surface 141.

[0151] A portion of the channel 132 defined between the second upper inner surface 140 and the second lower inner surface 141 may be shaped and arranged to guide the raw material 19 to the dunnage converter 60. In particular, the second upper inner surface 140 and the second lower inner surface 141 correspond to a portion of the channel 132 within the intake chute 120 that has the narrowest width, or left - right dimension, as shown in FIG. 8. Since the width and height of the portion near the outer end 102 of the inlet chute 120 are relatively low compared to the width and height of the portion near the inlet end 101, the raw material can be supplied to the inlet chute 120 without using another guide.

[0152] Accordingly, a 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 collect the raw material 19 supplied to the intake chute 120, while a 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 collected raw material 19 at a relatively accurate position of the outlet end 102 without the need for a guide.

[0153] Referring to FIG. 10, the lower wall 124 is provided with a radio - frequency identification (RFID) device 129 disposed adjacent to the outlet end 102, below the surfaces 128, 141. The RFID device 129 is configured to give an indication to a controller (not shown) of the dunnage converter 60 as to whether the inlet 100 is in a closed position or not. The controller is configured to permit the activation of the dunnage converter 60 only when the inlet 100 is in a closed position, that is, the controller is configured to prevent the activation of the dunnage converter 60 when the inlet 100 is in an open position, which helps to enhance the safety of users and other people near the dunnage converter 60.

[0154] In another embodiment, the first lower inner surface 122, the second lower inner surface 141, and the inclined surface 128 of the lower wall 124 can be formed as a single substantially planar surface, thereby reducing the possibility that the raw material 19 becomes clogged or caught when passing through the inlet chute 120.

[0155] Referring to FIG. 10, a part of the first upper inner surface 126 of the upper wall 123 forms a protrusion 125 that extends downward toward the lower wall 124. The protrusion 125, together with the opposing portion of the first lower inner surface 122 of the lower wall 124 on the opposite side of the protrusion 125, defines a restricting portion 127. The restricting portion 127 allows the raw material 19 to be supplied through the inlet chute 120, but prevents foreign objects from completely entering through the inlet chute 120. In particular, the restricting portion 127 is sized to allow the raw material 19 to pass through the inlet chute 120 while restricting the movement of thicker objects beyond the restricting portion 127 along the material path A. For example, when the user uses their hand to feed and pass the raw material 19 through the inlet chute 120, the relatively narrow restricting portion 127 prevents foreign objects from completely entering through the inlet chute 120. The restricting portion 127 prevents the user's finger from further entering into the inlet chute 120 beyond the restricting portion 127. In this way, the restricting portion 127 functions as a safety feature that can reduce or eliminate the possibility of the user's finger or hand being inadvertently drawn into the damage converter 60. Also, the restricting portion 127 prevents other objects from reaching the damage converter 60 via the inlet chute 120 and reduces the possibility of the damage converter 60 being damaged by objects other than the raw material 19 that are taken in.

[0156] The protrusion 125 can be formed as a part of the lower wall 124 and, in another embodiment, can extend toward the upper wall 123. For example, this configuration can be used in an embodiment where the raw material 19 is supplied to the inlet 100 from above the inlet 100 and moves along the upper wall 123 of the inlet chute 120. In these types of embodiments, the inner surface of the upper wall 123 is substantially flat, and the lower wall 124 defines a protrusion 125 that extends into the channel 132 and defines the restricting portion 127.

[0157] As shown in FIG. 10, the protrusion 125 is disposed closer to the inlet end 101 of the inlet chute 120 than to the outlet end 102. In another embodiment, the protrusion 125 can be disposed closer to the outlet end 102 than to the inlet end 101. For example, when the raw material 19 is inserted into the inlet chute 120, in applications that require a greater guide, the protrusion 125 can be disposed closer to the outlet end 102. With this feature, the user can guide the raw material 19 further downward in the channel 132, but a limitation is still provided that prevents the user from fully inserting their hand into the inlet chute 120. Also, in this configuration, in contrast to the configuration of the protrusion 125 shown in FIG. 10, a part of the first upper inner surface 126 that forms the upstream side of the protrusion 125 is at a more gentle angle with respect to the horizontal direction than a part of the first upper inner surface 126 that forms the downstream side of the protrusion 125.

[0158] Referring to FIG. 10, the protrusion 125 is substantially curved. In another embodiment, the protrusion 125 has a triangular cross-section, and the lowest part of the protrusion 125 forms a tip. The tip is considered to be particularly effective in preventing foreign objects from passing through the inlet chute 120.

[0159] In the embodiment shown in FIG. 10, a part of the first upper inner surface 126 that forms the upstream side of the protrusion 125 is inclined at a more acute angle with respect to the horizontal direction than a part of the first upper inner surface 126 that forms the downstream side of the protrusion 125. In another embodiment, the relative orientation of the upstream and downstream sides of the protrusion 125 may be the same as or opposite to the orientation shown in FIG. 10. Also, the height, or vertical dimension, of the protrusion 125 may be different from that shown in FIG. 10.

[0160] Figures 11 to 13 show the cutting mechanism 200 of the dunnage converter 60 coupled to the frame 63. For clarity, certain components of the dunnage converter 60 are not shown in Figures 11 to 13. In particular, Figure 11 shows the cutting mechanism 200 and the frame 63 without the housing 61 and the outlet chute 62. Figure 12 shows the cutting mechanism 200 and the frame 63 without the housing 61, the outlet chute 62, and the cutting motor assembly 201. Figure 13 shows the cutting mechanism 200 and the frame 63 without the housing 61, the outlet chute 62, the cutting motor assembly 201, and the cover 210 of the dunnage converter 60. Figures 14 and 15 are exploded views of the cutting mechanism 200.

[0161] 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.

[0162] As shown in Figures 14 and 15, the cover 210 is provided with a recess 212 configured to accommodate the crank 202, a hole 213 configured to accommodate components of the cutting motor assembly 201, and an opening 214 configured to accommodate fasteners. The cover 210 is also provided with side walls 215 shown in Figures 18 to 24, and these side walls 215 define a space with the cover 210 for accommodating the shuttle 230.

[0163] Referring to Figures 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 legs 208 that form a hole 206 therebetween.

[0164] The cutting motor assembly 201, the cover 210, and the crank 202 are assembled by inserting the motor extension 205 into the hole 213 of the cover 210 and connecting the motor body 207 to the cover 210 using a fastener that is inserted into the opening 214 of the cover 210 and engages the motor body 207. The crank 202 is connected to the cutting motor assembly 201 by inserting the crank 202 into the recess 212 of the cover 210 and inserting the motor extension 205 into the hole 206 of the crank 202. The legs 208 that define the hole 206 are compressed together to fix the crank 202 to the motor extension 205, and the rotation of the motor extension 205 gives a corresponding rotation to the crank 202.

[0165] As described below, the shuttle 230 is configured to engage with the cutting portion 220 such that the movement of the shuttle 230 gives a corresponding movement to the cutting portion 220. Referring to FIG. 16, the shuttle 230 includes mating features, such as in the form of an arm or a protrusion 233, that couple the shuttle 230 to the cutting portion 220. The protrusion 233 has a base 236 and a wing portion 235. The wing portion 235 extends laterally from the base 236 at an angle that is substantially perpendicular to the base 236. In another embodiment, the wing portion 235 can extend from the base 236 at another angle, for example, from about 10 degrees to about 80 degrees. Also, in another embodiment of the protrusion 233, there may be fewer than two or more than two wing portions 235. The protrusion 233 can include one wing portion 235, for example, to minimize manufacturing costs. Two or more wing portions 235 can also be used, for example, to enhance the engagement between the protrusion 233 and the cutting portion 220.

[0166] The protrusion 233 and the rest of the shuttle 230 are integrally formed. In another embodiment, the protrusion 233 can be made removable from the rest of the shuttle 230 to increase the customizability by the user, for example, allowing the user to select a specific design of the protrusion 233.

[0167] In another alternative embodiment, a protrusion 233 can be formed on the cutting part 220, and an opening can be provided in the shuttle 230 to receive the protrusion 233. With this function, more material can be arranged in the central part of the cutting part 220, for example, the structural integrity of the cutting part 220 can be enhanced. Further, the shuttle 230 can be provided with additional engaging functions such as additional recesses or magnets arranged in the recesses to enhance the engagement between the shuttle 230 and the backing surface (see the following description).

[0168] As shown in FIG. 16, the shuttle 230 includes side walls 237 that define an opening 238 therebetween. The opening 238 is configured to accommodate the cutting part 220. The side walls 237 help to enhance the lateral stability of the cutting part 220 with respect to the shuttle 230.

[0169] Referring to FIGS. 14 and 15, the cutting part 220 defines a receiving slot 221 configured to receive the protrusion 233 of the shuttle 230. The receiving slot 221 is sized and shaped such that the protrusion 233 fits within the receiving slot 221 with a minimal gap. By the engagement between the protrusion 233 and the cutting part 220, and the engagement between the cutting part 220 and the side walls 237, the cutting part 220 is constrained with respect to the shuttle 230. For example, the base 236 helps to limit the movement of the cutting part 220 in a first direction, i.e., the lateral direction, with respect to the shuttle 230, while the wing part 235 helps to limit the movement of the cutting part 220 in a second direction different from the first direction, i.e., the cutting direction B and the movement along the cutting plane, which will be further described below. In this way, the movement of the shuttle 230 causes the cutting part 220 to move.

[0170] As shown in FIG. 16, shuttle 230 defines a track in the form of, for example, a linear guide slot 231. Shuttle 230 also includes, for example, an access opening to the guide slot in the form of an inlet slot 234. Guide slot 231 is configured to receive the end of crank arm 204 of crank 202, and crank arm 204 can move between the ends of guide slot 231. Thus, guide slot 231 defines a linear axis along which crank arm 204 can move. Inlet slot 234 extends transversely to the axis of guide slot 231. Inlet slot 234 extends between the side surface of shuttle 230 and guide slot 231. Thus, inlet slot 234 facilitates the entry and exit of crank arm 204 into and out of guide slot 231.

[0171] Referring to FIG. 14, cutting portion 220 defines a recess 222. Recess 222 is configured to receive magnet 203 of cutting mechanism 200, and magnet 203 can apply a magnetic force that presses cutting portion 220 against the backing surface, i.e., the backing surface 243 of anvil portion 240. Anvil portion 240 is attached to frame 63 and remains stationary relative to cutting portion 222 and shuttle 230 as cutting portion 222 and shuttle 230 move in the cutting direction B shown in FIG. 17. The magnetic force serves to hold cutting portion 220 flush against backing surface 243 as cutting portion 222 slides in the cutting direction along backing surface 243. When the backing surface is substantially planar, such as backing surface 243, when cutting portion 220 engages the backing surface, cutting portion 220 moves along the cutting surface. Thus, when cutting portion 220 engages shuttle 230 in the above manner and magnet 203 magnetically couples cutting portion 220 to anvil portion 240, the movement of shuttle 230 linearly drives cutting portion 220 in the cutting direction B.

[0172] In another embodiment, the cutting portion 220 can have a different number of recesses and corresponding magnets 203 than those disclosed herein. For example, in some embodiments, to minimize manufacturing costs, it can include only a single recess for a single magnet. In other embodiments, to increase the magnetic force that couples the cutting portion 220 to the anvil portion 240, it can include two or more recesses and two or more magnets. In yet another alternative embodiment, the cutting portion 220 and the anvil portion 240 can be configured such that the cutting portion 220 is fixed and the shuttle 230 carries the anvil portion 240 and moves the anvil portion 240 in the cutting direction relative to the cutting portion 220.

[0173] As shown in FIGS. 14, 18, and 24, the cutting portion 220 is configured as a blade including a cutting edge 223. The tip of the cutting edge 223 has a sharp tip, which helps the cutting edge 223 to efficiently initiate cutting. In another embodiment, the tip can be of other shapes. For example, to avoid excessive pressure on a relatively narrow area of the dunnage being cut, the tip can have a curved tip.

[0174] In another embodiment, the cutting edge 223 can have a rounded or blunt tip to initiate cutting. For example, when the cutting portion 220 presses the dunnage against an opposing surface having a sharp edge, such as an anvil having a sharp edge, if the cutting portion 220 is moving at a sufficient speed to cut the dunnage, the cutting portion 220 can cut the dunnage even without a sharp edge on the cutting portion 220. In yet another alternative embodiment, the cutting edge 223 can be serrated and can comprise multiple teeth, a blade with shallow teeth, or other configurations. The multiple teeth are defined by points separated by grooves disposed therebetween.

[0175] The cutting blade 223 is illustrated as having a single tip that forms the tip of the cutting blade 223. In another embodiment, the cutting blade 223 can include multiple tips to facilitate the cutting of the dunnage. The tips can be arranged alternately such that there is one or more tip portions and multiple rear portions. Alternatively, all the tips can be evenly aligned and configured such that there are no tip portions or rear portions.

[0176] The cutting blade 223 is symmetrically disposed around the tip of the cutting blade 223, and the cutting blade 223 is composed of two substantially identical halves. As shown in FIGS. 14, 18, and 24, each half is substantially straight and angled with respect to the moving direction of the cutting blade 223. Thus, when the cutting blade 223 cuts the dunnage, the cutting blade 223 pushes a part of the dunnage laterally, i.e., towards the side surface of the cutting portion 220. In another embodiment, the cutting blade 223 is asymmetrically disposed around the tip of the cutting blade, and / or the halves of the cutting blade 223 have a curved shape, which can change the distribution of the pressure exerted by the cutting blade 223 on the dunnage.

[0177] In another embodiment, the cutting portion 220 can have a configuration other than a blade. For example, in another embodiment, the cutting portion 220 can be configured as a wire, a knife, or other types of cutting devices.

[0178] As shown in FIGS. 14 and 24, the anvil portion 240 defines a substantially C-shaped track 241 and an opening 244. The anvil portion 240 includes an anvil 242 and a backing surface 243. The backing surface 243 is substantially smooth, facilitating the sliding movement of the cutting portion 220 thereon. As described above, the magnet 203 holds the cutting portion 220 flush against the backing surface 243.

[0179] Also, as described above, a part 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 along a substantially C-shaped path within the track 241. The track 241 is shown in FIG. 14.

[0180] As shown in FIGS. 11 to 13, the opening 244 of the anvil portion 240 is configured to accommodate a fixture for fixing the anvil portion 240 to the frame 63 of the dunnage converter 60. As described above, the anvil portion 240 remains stationary with respect to the cutting portion 220 and the shuttle 230.

[0181] As shown in FIGS. 14 and 15, the anvil 242 has a convex tip and a substantially linear side surface. Due to the convex shape of the tip, a part of the dunnage pressed against the anvil 242 is pressed against the convex tip, and the remaining part of the dunnage wraps around the convex edge. Thereby, for example, when the dunnage is cut by the cutting blade on the opposite side, that is, the cutting blade 223 of the cutting portion 220, the dunnage is pressed laterally, and the pressure on the anvil 242 is more evenly distributed.

[0182] Due to the convex profile of the tip of the anvil 242, the pressure of the bundled material is more smoothly distributed with respect to the anvil portion 240. However, in other embodiments, the tip of the anvil 242 can have a different shape such as a sharp tip to provide different pressure dispersion for the dunnage. Similarly, the anvil portion 240 can have two or more tips to provide different pressure dispersion for the dunnage.

[0183] Figure 17 is a top view of the cutting part 220 and the anvil part 240 in an assembled state. The abutting surfaces 243 of the cutting part 220 and the anvil part 240 are flush with each other, which helps to cleanly cut the dunnage when the cutting part 220 moves in the cutting direction B along the cutting surface with respect to the anvil part 240. As shown in FIGS. 13, 14, and 17, the cutting blade 223 is inclined, and when the dunnage is cut, the dunnage is pushed out from the cutting part 220. The inclined surface of the cutting blade 223 has a substantially straight or linear inclination. The inclined surface of the cutting blade 223 may be curved in another embodiment. For example, the inclined surface can have a concave profile, that is, the inclined surface can curve inward toward the anvil part, thereby increasing the sharpness of the cutting blade 223.

[0184] As shown in FIGS. 14 and 15, the surface of the anvil 242 that contacts and constrains the dunnage has a convex shape and is not angled or chamfered to form a blunt, i.e., sharp, cutting edge. In another embodiment, the above surface of the anvil 242 can be composed of a sharp cutting edge to assist in cutting the dunnage when the cutting part 220 moves in the cutting direction B.

[0185] FIGS. 18 to 20 show the cutting mechanism 200 in an assembled and in-use state. In the assembled state, the cutting part 220 and the anvil 242 define a window through which the dunnage passes after being converted by the drive mechanism 300 as described below. FIG. 18 shows the cutting mechanism 200 in the home position. In the home position, the cutting part 220 is at the farthest distance from the anvil 242, and the window is at its maximum size. Also, the crank arm 204 of the crank 202 is disposed substantially at the center of the guide slot 231. When in this central position, the crank arm 204 is in line with the inlet slot 234. This is the position of the crank arm 204 and the crank 202 at the start of the cutting cycle. In another embodiment, the crank arm 204 can be disposed at other positions within the guide slot 231 at the start of the cutting cycle.

[0186] Figure 19 shows the cutting mechanism 200 in the intermediate position. The crank arm 204 rotates about 90 degrees clockwise along the track 241 and moves towards the end of the guide slot 231. Due to this movement of the crank arm 204, the crank arm 204 moves the shuttle 230 and the cutting part 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 as shown in FIGS. 18 to 24. Thereby, when the crank arm 204 rotates, the shuttle 230 moves linearly in the cutting direction B.

[0187] Since the cutting part 220 is coupled to the shuttle 230 via the protrusion 233, the cutting part 220 moves in the cutting direction B together with the shuttle 230. Also, the magnet 203 that magnetically couples the cutting part 220 to the anvil part 240 helps to hold the cutting part 220 flush with the backing surface 243 of the anvil part 220 when the cutting part 220 slides with respect to the backing surface 243 in the cutting direction B.

[0188] As the cutting mechanism 200 moves towards the intermediate position, passes through the intermediate position, and the cutting part 220 moves in the cutting direction B, the size of the window formed between the cutting part 220 and the anvil 242 becomes smaller. More specifically, as the cutting edge 223 of the cutting part 220 approaches the tip of the anvil 242, the size of the window becomes smaller. When the dunnage is located within the window, the cutting edge 223 starts cutting the dunnage when the cutting mechanism 200 is generally in the intermediate position, as during the normal operation of the dunnage converter 60. The intermediate position is shown as being at the position where the crank arm 204 has rotated 1 / 4 turn along the track 241 with respect to the position of the crank arm 204 when the cutting mechanism 200 is in the home position. However, in another embodiment, the cutting mechanism 200 can be configured such that the "intermediate position" is any position of the cutting mechanism 200 between the home position and the end position of the cutting mechanism 200, as described below.

[0189] Figure 20 shows the cutting mechanism 200 in its end position. At this position, the crank arm 204 has 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 home position, that is, a position offset by approximately 180 degrees. As also shown in Figure 20, the window previously defined between the cutting part 220 and the anvil 242 is closed, that is, no longer exists, because the cutting part 220 has passed through the anvil 242. Although not shown, the dunnage that was in the window is pressed against the anvil 242 and cut by the cutting blade 223 of the cutting part 220 when the cutting part 220 advances in the cutting direction B and reaches the position shown in Figure 20. Thereby, the portion of the dunnage that passed through the window following the previous cutting cycle is cut, and another dunnage piece is formed. Next, the newly cut dunnage piece is discharged from the dunnage converter 60 through the outlet chute 62.

[0190] After the cutting mechanism 200 reaches the end position, if the crank arm 204 continues to rotate in the clockwise direction, the crank arm 204 will finally return to the home position shown in Figure 18. As the crank arm 204 moves within the guide slot 231 and the track 241, the crank arm 204, the shuttle 230, and the anvil part 240 interact, and the cutting mechanism 200 returns to the home position shown in Figure 18. As shown in Figure 18, the shuttle 230 and the cutting part 220 are moving in a direction opposite to the cutting direction B, the window between the cutting part 220 and the anvil 242 is completely opened again, and when the next cutting cycle starts, it can receive the advancing dunnage flow.

[0191] As shown in Figure 20, 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 part 240. In another embodiment, when the cutting mechanism 200 is in the end position, the end of the shuttle 230 can be configured not to extend beyond the anvil part 240 or the side wall 215. For example, the length of the shuttle 230, that is, the left - right dimension, can be shortened so that the shuttle 230 stays within the boundary defined between the side walls 215, reducing the space required to accommodate the dunnage converter 60.

[0192] Figures 21 - 24 show the shuttle 230, the attached cutting portion 220, and the magnet 203 detached from the rest of the cutting mechanism 200. In particular, FIGS. 21 and 22 show the shuttle 230, the cutting portion 220, and the magnet 203 detached when the cutting mechanism 200 is in the home position. FIGS. 23 and 24 show the shuttle 230, the cutting portion 220, and the magnet 203 detached when the cutting mechanism 200 is in the end position.

[0193] In either the home position or the end position, the shuttle 230 can be released only when the crank arm 204 is aligned with the inlet slot 234 of the shuttle 230. When the crank arm 204 is in another position, i.e., when the cutting mechanism 200 is in an intermediate position between the home position and the end position, the crank arm 204 is located within a guide slot 231 that is not aligned with the inlet slot 234. As a result, interference occurs between the crank arm 204 and the peripheral portion of the guide slot 231, preventing the shuttle 230 from being released from the rest of the cutting mechanism 200. This function ensures that when the user attempts to remove the shuttle 230, the cutting mechanism 200 is not cutting the dunnage, improving the safety of the user.

[0194] As shown in FIGS. 21 to 24, by moving the shuttle 230 in the cutting direction B, the shuttle 230 is separated from the remaining part of the cutting mechanism 200, and the crank arm 204 passes through the inlet slot 234. The separation path is linear because the shuttle 230 is restricted to linear movement by the side wall 215. In another embodiment where the shuttle 230 is not restricted to linear movement, the shuttle 230 can be separated by moving it along a non-linear separation path. The non-linear separation path can reduce the possibility that the shuttle 230 accidentally detaches or is misaligned during the normal dunnage manufacturing operation of the dunnage converter 60. This is because in order to separate the shuttle 230 under such circumstances, it is necessary for the shuttle 230 to follow a separation path that it does not follow during normal operation.

[0195] The separation path of the shuttle 230 is along the cutting surface because the magnet 203 maintains the cutting part 220 and thus holds the shuttle 230 flush with the anvil part 240. In other embodiments, the separation path may be transverse to the cutting surface. For example, in an embodiment where the cutting motor assembly 201 can be separated from the cutting mechanism 200, the shuttle 230 can be lifted from the anvil part 240 during separation to separate the shuttle 230 from the cutting mechanism 200.

[0196] In the cutting mechanism 200, the shuttle 230 is released by moving it in the cutting direction B. This function reduces the possibility of the user being injured because even if the user loses the grip force on the shuttle 230 during the cutting process, the user's hand moves away from rather than approaching the cutting blade 223 of the cutting part 220. In another embodiment, the shuttle 230 can be released from the cutting mechanism 200 by offsetting from the side wall 215, that is, moving outward and then lifting.

[0197] Figures 25 to 28 show the rollers 310 and 320 of the drive assembly 300 shown in Figure 7. The rollers 310 and 320 are configured to compress the raw material 19 entering the dunnage converter 60 to convert the raw material 19 into dunnage 15 and convey the dunnage 15 from the dunnage converter 60 through the dunnage converter 60.

[0198] As shown in Figure 25, the roller 310 has an outer surface 311 and defines a channel 312. The channel 312 is configured to accommodate the spindle 66 shown in Figure 7, and the roller 310 can rotate around the spindle 66. The roller 310 is in an idle state, that is, the roller 310 is not driven by a motor. The roller 310 is driven to rotate by interaction with the rotating roller 320 through the outer surface 311. In another embodiment, the roller 310 can be driven by the motor of the drive assembly 300.

[0199] The outer surface 311 is substantially smooth and made of a substantially non-sticky material. For example, the surface 311 can be made of silicone. In another embodiment, the outer surface 311 of the roller 310 may not be smooth.

[0200] The outer surface of the roller 320 has a different shape or profile from the outer surface of the roller 310. The roller 320 defines a channel 322 shown in Figure 26. The channel 322 is configured to accommodate the driving component (not shown) of the feed motor 301, and the feed motor 301 can rotationally drive the roller 320. In another embodiment, the roller 320 is in an idle state and may be driven by the roller 310.

[0201] The roller 320 includes an outer surface 323. The outer surface 323 defines a plurality of grooves 321 that extend in the circumferential direction. The grooves 321 are arranged side by side along the length, or height, of the roller 320, and each groove 321 is symmetrically arranged about the longitudinal axis of the roller 320. The lower end, or inner end, of each groove 321 is defined by a surface of the roller 320 that is substantially perpendicular to the longitudinal axis of the roller 320 as viewed from the perspective of FIG. 28. Each groove 321 is configured to receive a corresponding toroidal-shaped ridge 325 of the roller 320, as shown in FIG. 28. FIG. 27 shows one of the ridges 325 alone.

[0202] The ridge 325 is, for example, an O-ring formed from a flexible material. The ridge 325 functions as a non-planar contact surface that is pressed against the outer surface 311 of the roller 310, as shown in FIG. 28. The ridge 325 has a substantially circular cross-section and is sized to extend beyond the outer surface 323 of the roller 320. As shown in FIG. 28, the ridge 325 extends beyond the outer surface 323 by a substantially equal distance. The ridge 325 thus defines protrusions, as well as hills and valleys, on the outer surface of the roller 320.

[0203] In another embodiment, the ridge 325 and the remainder of the roller 320 may be integrally formed. For example, the protrusions, as well as the hills and valleys, defined by the ridge 325 may be formed on an integral-type embodiment of the roller 320.

[0204] During operation of the dunnage converter 60, the raw material 19 is drawn between the rollers 310, 320 by the rollers 310, 320 from the supply station 13 via the inlet 100. The outer surface 311 of the roller 310 opposite the ridge 325 applies pressure to the raw material 19. The pressure profile varies along the width, or transverse direction, of the raw material 19. This pressure causes the raw material 19 to be crumpled and deformed, converting the raw material 19 into dunnage.

[0205] The raised portion 325 includes a tip from a plane 323 that is substantially perpendicular to the plane 323. In another embodiment, the raised portion 325 can have a tip at an angle different from the plane 323 to provide a different pressure profile for the roller 310. For example, the raised portion 325 can be shaped to have a tip from 0 to 45° from the surface of the roller 320.

[0206] In another embodiment, the raised portion 325 has a shape other than a torus and / or has a non-circular cross-section, and can generate a pressure profile different from the pressure profile generated by the raised portion 325, thereby changing the shape of the dunnage generated by the dunnage converter 60. For example, in another embodiment of the raised portion 325, it can have a surface that is one or more planes defining a bent portion facing outward.

[0207] Also, in another embodiment, the raised portion 325 and the groove 321 can be configured such that the raised portion 325 extends different distances beyond the outer surface 323 of the roller 320, further changing the pressure profile generated by the raised portion 325 and the outer surface 311 of the roller 310. Also, in another embodiment of the roller 320, the groove 321 can be configured to extend in a plane inclined with respect to the longitudinal axis of the roller 320, i.e., not perpendicular. Also, one or more of the grooves 321 can have a direction different from the direction of the other grooves 321.

[0208] Another embodiment of the system 10 can include a dunnage converter 60 that includes a conventional roller, or a device that converts the raw material 19 into dunnage 15 using hardware other than a roller (such as a paper crumpling machine).

[0209] One of ordinary skill in the art should understand that there are many types and sizes of dunnage that may need or want to be manufactured, stored, and / or discharged, and another embodiment of the system 10 can be configured to manufacture such dunnage.

[0210] As used herein, the terms "upper", "lower", and / or other terms indicating direction are used for convenience to indicate the relative position and / or direction between the various parts of the embodiments. It can be understood that a particular embodiment or a part thereof can be oriented in other positions. Also, the term "about" should generally be understood to refer to both the corresponding numerical value and the range of numerical values. Further, all numerical ranges in this specification should be understood to include all integers within the range.

[0211] In this specification, specific features, functions, components, and parts have been described in accordance with the teachings of the present disclosure, but the scope of this patent is not limited thereto. Rather, this patent encompasses all embodiments of the teachings of the present disclosure that fall within the scope of acceptable equivalents. Also, although exemplary embodiments of the present invention are disclosed herein, it will be understood by those skilled in the art that numerous changes and other embodiments can be conceived. For example, the features of various embodiments can be used in other embodiments, and the appended claims are intended to cover all such changes and embodiments that are within the spirit and scope of the present invention. For example, the inlet 100 and its other embodiments can be used in combination with a dunnage converter other than the dunnage converter 60. Similarly, the cutting mechanism 200 and its other embodiments can be incorporated into a dunnage converter that does not include the drive assembly 300. Similarly, the drive assembly 300 and its other embodiments can be incorporated into a dunnage converter that does not include the cutting assembly 200.

[0212] Conditional language such as "can", "could", "might", "may", etc. generally serves to convey that, unless otherwise specified or understood in a different way within the context in which it is used, a particular implementation may include certain features, elements, and / or operations, but may not include them in other implementations. Thus, such conditional language generally is not intended to imply that features, elements, and / or methods are in any way required in one or more implementations, or that these features, elements, and / or methods are included in, or are performed in, a particular implementation.

[0213] Many modifications and other implementations of the disclosure herein will be apparent in light of the teachings shown in the foregoing description and the related drawings. Accordingly, it is to be understood that the disclosure is not limited to the particular implementations disclosed, and that modifications and other implementations are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A drive mechanism configured to transform raw materials into dunnage, A cutting mechanism, The aforementioned cutting mechanism is An anvil having a curved convex surface, Shuttle and A cutting section moved by the shuttle, A dunnage converter in which the cutting section moves relative to the anvil due to the movement of the shuttle, thereby cutting the dunnage.

2. The dunnage converter according to claim 1, wherein the anvil is configured such that when the cutting portion or the anvil cuts the dunnage, the dunnage is pressed around the curved convex surface of the anvil.

3. The dunnage converter according to claim 2, wherein the anvil has an opening defined therein, configured to allow the dunnage to pass through the anvil, and the opening is at least partially defined by the convex surface.

4. The anvil further includes first and second sides, The anvil has an opening defined by the curved surface and the first and second sides, The dunnage converter according to claim 1, wherein the anvil is configured such that when the cutting portion of the anvil moves and cuts the dunnage, the dunnage is pushed toward the first and second sides.

5. The dunnage converter according to claim 1, wherein the curved surface of the anvil includes a sharp edge configured to cut the dunnage.

6. The dunnage converter according to claim 1, wherein the cutting mechanism further includes a magnet attached to one of the cutting portion and the anvil, and configured to magnetically and slidably connect the cutting portion and the anvil.

7. A drive mechanism configured to transform raw materials into dunnage, A cutting mechanism including a shuttle and a cutting section moved by the shuttle, The movement of the shuttle causes the cutting section to move, cutting the dunnage. The shuttle and the cutting mechanism each include a projection having a base and a wing portion extending laterally from the base, The shuttle and the other cutting mechanism are configured to receive the projection, The projection is configured to engage with the shuttle and the other of the cutting mechanism. The engagement of the projection with the shuttle and the other part of the cutting mechanism causes the shuttle to be connected to the cutting portion. The movement of the cutting portion in the first direction relative to the shuttle is restricted by the base. A dunnage converter in which the movement of the cutting portion in a second direction perpendicular to the first direction relative to the shuttle is restricted by the wing portion.

8. The dunnage converter according to claim 7, wherein the drive mechanism includes one or more rollers.

9. The one or more rollers include a first roller and a second roller, The first roller includes an outer surface having a first shape, The dunnage converter according to claim 8, wherein the second roller includes an outer surface having a second shape different from the first shape.

10. The dunnage converter according to claim 7, wherein the cutting portion includes a blade.

11. Further comprising an intake including an inlet chute configured to supply a line of high-density material to the dunnage converter, 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 channel, The internal channel is configured to form part of the material path of the raw material through which the high-density material is supplied to the dunnage converter. The second surface is configured to form a projection extending toward the first surface. The dunnage converter according to claim 7, wherein the opposing portions of the projection and the first surface define a limiting portion within the internal channel.

12. Furthermore, An inlet chute configured to supply the aforementioned raw materials to the dunnage converter, Includes an intake, which includes a guide configured to guide the raw materials into the inlet chute, The dunnage converter according to claim 7, wherein the guide defines an opening configured to receive the raw material.

13. The dunnage converter according to claim 7, A system including the aforementioned raw material supply unit.

14. A drive mechanism configured to transform raw materials into dunnage, A cutting mechanism, The cutting mechanism is, Shuttle and A cutting section that moves by the movement of the shuttle, A motor assembly including a rotatable crank coupled to the shuttle, configured such that the rotation of the crank causes the shuttle to move along a plane, A dunnage converter is configured such that the shuttle is detached from the crank by moving the shuttle along a plane when the crank is at a first angular position relative to the shuttle.

15. The shuttle is configured such that when the crank moves from the first angular position to the second angular position, the cutting portion moves along the plane to cut the dunnage. The dunnage converter according to claim 14, wherein the second angular position is offset by approximately 180 degrees from the first angular position.

16. 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, The dunnage converter according to claim 14, wherein the crank is configured to engage with the shuttle via the track.

17. The shuttle further defines an opening adjacent to the track, The crank includes a projection, The track is configured to receive the projection, The dunnage converter according to claim 14, wherein the shuttle is further configured to detach from the crank when the projection is aligned with the opening.

18. The dunnage converter according to claim 14, wherein the shuttle is further configured such that the projection aligns with the opening only when the crank is in the first or second angular position.

19. A dunnage converter configured to transform raw materials into dunnage, The intake includes an inlet chute configured to supply the raw materials to the dunnage converter, The entrance 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 channel, The internal channel is configured to form part of the material path of the raw material that is supplied to the dunnage converter. The second surface is located downstream of the inlet end of the inlet chute and includes a projection extending toward the opposite side of the first surface. A dunnage manufacturing system wherein the projection narrows the internal channel by locally reducing the height of the internal channel between the projection and the opposite side of the first surface.

20. The dunnage manufacturing system according to claim 19, wherein the dunnage converter includes one or more rollers.

21. The projection is configured to allow the raw material to be manually pushed over the projection, The dunnage manufacturing system according to claim 19, wherein the projection is further configured to prevent the user's palm from moving over the projection.

22. The limiting portion is configured to allow the high-density material to move beyond the limiting portion. The dunnage manufacturing system according to claim 19, wherein the limiting portion is further configured to prevent the user's fingers and / or hands from moving beyond the limiting portion.

23. The dunnage manufacturing system according to claim 19, wherein the first surface is substantially planar.

24. The dunnage manufacturing system according to claim 19, wherein the first surface is flat.

25. The dunnage manufacturing system according to claim 19, wherein the first surface has a large radius of curvature.

26. The dunnage manufacturing system according to claim 19, wherein the first surface has a radius of curvature greater than approximately 10 feet.

27. The dunnage manufacturing system according to claim 23, wherein the first surface is substantially planar along the entire length of the first wall.

28. The dunnage manufacturing system according to claim 19, wherein the first wall is the lower wall of the inlet chute, and the second wall is the upper wall of the inlet chute.

29. The dunnage manufacturing system according to claim 19, wherein the projection is positioned closer to the inlet end than to the outlet end.

30. The second surface is inclined downstream at a first angle between the projection and the outlet end of the inlet chute, The second wall is inclined upstream at a second angle between the projection and the outlet end of the inlet chute, The dunnage manufacturing system according to claim 19, wherein the first angle is greater than the second angle.

31. A dunnage converter configured to transform raw materials into dunnage, Including an intake, The aforementioned intake is, An inlet chute configured to supply the aforementioned raw materials to the dunnage converter, Includes a guide configured to guide the raw materials into the inlet chute, The guide defines an opening configured to receive the raw material, The opening is partially defined by the first guide surface of the guide, The first guide surface is configured to guide the raw material to the inlet chute in the first configuration, The dunnage conversion system comprises a second guide surface configured to guide the raw material to the inlet chute in a second configuration.

32. The dunnage conversion system according to claim 31, wherein the second guide surface is the tip of the guide.

33. The dunnage conversion system according to claim 31, wherein the second configuration is in a planar state.

34. The dunnage conversion system according to claim 33, wherein the width of the second guide surface is approximately equal to the width of the raw material when the raw material is in a planar state.

35. The dunnage conversion system according to claim 31, wherein the first guide surface is disposed between the inlet chute and the second guide surface.

36. The dunnage conversion system according to claim 31, wherein the first configuration is in a non-planar state.

37. The dunnage conversion system according to claim 36, wherein the first configuration is a twisted configuration.

38. The opening extends through the upper surface of the guide, The dunnage conversion system according to claim 31, wherein the first guide surface is substantially perpendicular to the upper surface of the guide.

39. The dunnage conversion system according to claim 31, wherein the second guide surface is configured to impart a bend of approximately 90 degrees to the raw material.

40. The dunnage conversion system according to claim 31, wherein the inlet chute defines an inlet opening for receiving the raw materials, and the width of the inlet opening is greater than the width of the opening.

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