Apparatus and method for dispensing an insulating dunnage product

Abstract

An insulated dunnage pad-making apparatus includes a supply assembly having expandable slit sheet material supply supports, each configured to support a roll of expandable slit sheet material, and one or more separator sheet material supply supports, each configured to support a roll of separator sheet material. A laminating assembly includes two cover sheet material supply supports, each configured to support a respective roll of cover sheet material. The laminating assembly is configured to selectively feed at least one layer of expandable slit sheet material in an expanded state in a downstream direction from the roll of expandable slit sheet material, feed two layers of cover sheet material in the downstream direction from the roll of cover sheet material, and laminate the at least one layer of expandable slit sheet material in between the two layers of cover sheet material to form a continuous strip of insulated dunnage padding.

Description

[0001] APPARATUS AND METHOD FOR DISPENSING AN INSULATING DUNNAGE PRODUCT

[0002] Field of the Invention

[0003] The present invention relates generally to the field of protective packaging material or dunnage, and more particularly to insulating dunnage products.

[0004] Background

[0005] Most refrigerated shipping solutions include a corrugated container with an internal thermal liner or barrier. Many of these thermal liners are constructed from materials which prohibit them from being curbside recyclable. A common insulated container for refrigerated shipping uses a molded polystyrene liner within a cardboard box. An ice pack or other cooling element may be placed in the container to keep the contents of the box cool during shipment. Additional layers of insulation, often covered by a plastic material, also may be used to separate the contents from direct contact with the cooling element and any moisture that may condense around the cooling element or nearby surfaces.

[0006] Despite functioning well during actual shipment, the current refrigerated shipping system has several problems. For example, the polystyrene liners require a lot of space for storage at and before shipment to the packaging center. Polystyrene and plastic coverings also are not readily recyclable, produce hazardous materials when burned, and because plastic does not readily decompose, it has a persistent presence in the environment.

[0007] Summary

[0008] The present disclosure provides an apparatus and method for making a paperbased insulating dunnage product that has adequate insulation properties to supplant some or all of the applications that currently require refrigerated shipment. The present disclosure provides a multi-layer variable thermal liner dunnage product that will allow a customer the option to change the performance of the dunnage product by adding or removing one or more layers within the dunnage product.

[0009] More specifically, the present disclosure provides a multi-layer and variable liner formed of one or more sheets of paper deformed out of their planar state to form a plurality of air pockets when layered, wrapped within an outer cover. Paper is a renewable resource, and can be recycled, composted, or burned with fewer and less hazardous byproducts than plastic materials, such as polystyrene. The liner is made of 100% curbside recyclable paper (e.g., kraft paper, tissue, and cellulose wadding) with a water vapor barrier outer coated kraft cover. The paper is relatively impermeable to air such that the dunnage product provides both cushioning and insulating properties.

[0010] The presently disclosed apparatus and method allows a customer the option to change the performance of the liner by adding or eliminating certain components or layers contained within the outer cover, and adjusting the dimensions (length, width, or thickness or combination thereof) of the insulating material to ensure efficient use of space in the container for maintaining the temperature in the container for the desired time. The insulating dunnage product can be produced on demand and with specific dimensions and cushioning and insulating properties, as needed. With this flexible system, a customer can tailor the insulating dunnage product for their specific needs which can result in lower costs, longer insulating duration, less damage or a combination of all these.

[0011] According to an aspect of the present disclosure, an insulated dunnage pad making apparatus includes a supply assembly having two or more expandable slit sheet material supply supports, each configured to support a respective roll of expandable slit sheet material. The insulated dunnage pad making apparatus also includes a laminating assembly downstream of the supply assembly. The laminating assembly includes two cover sheet material supply supports, each configured to support a respective roll of cover sheet material. The laminating assembly is configured to selectively feed at least one layer of expandable slit sheet material in the expanded state in a downstream direction from the respective roll of expandable slit sheet material supported by at least one of the two or more expandable slit sheet material supply supports, feed two layers of cover sheet material in the downstream direction from the respective roll of cover sheet material supported on each of the two cover sheet material supply supports, and laminate the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated dunnage padding for forming the insulated dunnage pad.

[0012] According to an embodiment of any paragraph(s) of the present disclosure, further including one or more separator sheet material supply supports, each configured to support a roll of separator sheet material, and the laminating assembly is configured to selectively feed at least two layers of expandable slit sheet material in the expanded state in the downstream direction from the respective roll of expandable slit sheet material supported by at least two of the two or more expandable slit sheet material supply supports and selectively feed at least one layer of separator sheet material in the downstream direction from the respective roll of separator sheet material supported by the one or more separator sheet material supply supports. The laminating assembly is then configured to laminate the at least one layer of separator sheet material in between each of the at least two layers of expandable slit sheet material.

[0013] According to an embodiment of any paragraph(s) of the present disclosure, the insulated dunnage pad making apparatus further includes a cutting assembly downstream of the laminating assembly. The cutting assembly is configured to cut the continuous strip of insulated padding to form the insulated dunnage pad.

[0014] According to an embodiment of any paragraph(s) of the present disclosure, the supply assembly further includes at least two expanders, each positioned adjacent a respective one of the at least two expandable slit sheet material supply supports. Each of the at least two expanders is configured to pull expandable slit sheet material from the respective roll of expandable slit sheet material in the downstream direction and expand the expandable slit sheet material from an unexpanded state to an expanded state.

[0015] According to an embodiment of any paragraph(s) of the present disclosure, the laminating assembly further includes an adhesive applicator assembly configured to deposit an adhesive on an upper surface of a bottom layer of cover sheet material of the two layers of cover sheet material.

[0016] According to an embodiment of any paragraph(s) of the present disclosure, the laminating assembly further includes a compression roller assembly configured to compress lateral edges of the two layers of cover sheet material together to seal the at least one layer of expandable slit sheet material therebetween.

[0017] According to an embodiment of any paragraph(s) of the present disclosure, the compression roller assembly includes a pair of compression rollers, each having a pair of compression collars for compressing the lateral edges of the two layers of cover sheet material together to seal the at least one layer of expandable slit sheet material therebetween.

[0018] According to an embodiment of any paragraph(s) of the present disclosure, the laminating assembly further includes a conveyor assembly configured to convey the continuous strip of insulated padding in the downstream direction.

[0019] According to an embodiment of any paragraph(s) of the present disclosure, the conveyor assembly includes a top conveyor having one or more top drive belts and a bottom conveyor having one or more bottom drive belts. The top and bottom drive belts are configured to convey the continuous strip of insulated padding therebetween in the downstream direction.

[0020] According to an embodiment of any paragraph(s) of the present disclosure, the insulated dunnage pad making apparatus also includes an exit conveyor assembly downstream of the laminating assembly for conveying the insulated dunnage pad. According to an embodiment of any paragraph(s) of the present disclosure, the exit conveyor assembly includes a creasing assembly for creasing the insulated dunnage pad.

[0021] According to another aspect of the present disclosure, a method of making an insulated dunnage pad includes the step of selectively feeding at least one layer of expandable slit sheet material in an expanded state in a downstream direction from at least one of two or more supplies of expandable slit sheet material. The method also includes the steps of feeding two layers of cover sheet material in the downstream direction from two supplies of cover sheet material and laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding. The method also includes the step of cutting the continuous strip of insulated padding along a direction perpendicular to the downstream direction to form the insulated dunnage pad.

[0022] According to an embodiment of any paragraph(s) of the present disclosure, the step of selectively feeding the at least one layer of expandable slit sheet material in the expanded state includes selectively feeding at least two layers of expandable slit sheet material in the expanded state in the downstream direction from at least two of the two or more supplies of expandable slit sheet material. The method further includes the step of selectively feeding at least one layer of separator sheet material in the downstream direction from at least one supply of separator sheet material.

[0023] According to an embodiment of any paragraph(s) of the present disclosure, the method further includes the step of laminating the at least one layer of separator sheet material in between each of the at least two layers of expandable slit sheet material in the expanded state.

[0024] According to an embodiment of any paragraph(s) of the present disclosure, the step of selectively feeding the at least one layer of expandable slit sheet material in the expanded state includes expanding at least one layer of expandable slit sheet material in an unexpanded state to an expanded state. According to an embodiment of any paragraph(s) of the present disclosure, the step of laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding includes depositing an adhesive on opposing lateral edges of an upper surface of a bottom layer of cover sheet material of the two layers of cover sheet material.

[0025] According to an embodiment of any paragraph(s) of the present disclosure, the step of laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding further includes compressing opposing lateral edges of the two layers of cover sheet material together to seal the at least one layer of expandable slit sheet material in the expanded state therebetween.

[0026] According to an embodiment of any paragraph(s) of the present disclosure, the step of laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding includes conveying the continuous strip of insulated padding in the downstream direction toward the cutting assembly.

[0027] According to an embodiment of any paragraph(s) of the present disclosure, the method further includes conveying the insulated dunnage pad in the downstream direction.

[0028] According to an embodiment of any paragraph(s) of the present disclosure, the method further includes creasing the insulated dunnage pad.

[0029] The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail one or more illustrative embodiments of the invention. These embodiments, however, are but a few of the various ways in which the principles of the invention can be employed. Other objects, advantages and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings. Brief Description of the Drawings

[0030] FIG. 1 A is a schematic illustration of an insulated dunnage pad making apparatus.

[0031] FIG. 1 B is schematic illustration of an insulated dunnage pad making apparatus.

[0032] FIG. 2A is a cross-sectional view of an insulated dunnage pad.

[0033] FIG. 2B is a cross-sectional view of an insulated dunnage pad.

[0034] FIG. 3A is a schematic illustration of an insulated dunnage pad making apparatus.

[0035] FIG. 3B is a schematic illustration of an insulated dunnage pad making apparatus.

[0036] FIG. 4A is a cross-sectional view of an insulated dunnage pad.

[0037] FIG. 4B is a cross-sectional view of an insulated dunnage pad.

[0038] FIG. 40 is a perspective view of an insulated dunnage pad partially in section to show the interior layers.

[0039] FIG. 5 is a perspective view of an insulated dunnage pad making apparatus.

[0040] FIG. 6 is a perspective view of a supply assembly of an insulated dunnage pad making apparatus.

[0041] FIG. 7 is a perspective view of an insulated dunnage pad making apparatus.

[0042] FIG. 8 is a perspective view of a supply assembly of an insulated dunnage pad making apparatus.

[0043] FIG. 9 is a cross-sectional view of a supply assembly of an insulated dunnage pad making apparatus.

[0044] FIG. 10 is a perspective view of a laminating assembly of an insulated dunnage pad making apparatus.

[0045] FIG. 11 is a perspective view of a laminating assembly of an insulated dunnage pad making apparatus. FIG. 12 is a perspective view of a laminating assembly of an insulated dunnage pad making apparatus.

[0046] FIG. 13 is a cross-sectional view of a laminating assembly of an insulated dunnage pad making apparatus.

[0047] FIG. 14A is a perspective view of a cutting assembly of an insulated dunnage pad making apparatus.

[0048] FIG. 14B is a perspective view of a cutting assembly of an insulated dunnage pad making apparatus.

[0049] FIG. 14C is an enlarged sectional view of FIG. 14A as seen along lines 14C- 14C.

[0050] FIG. 15 is a perspective view of an exit conveyor assembly portion of an insulated dunnage pad making apparatus.

[0051] Detailed Description

[0052] When reduced to practice, the present disclosure can take many different forms. For the purpose of promoting an understanding of the principles of the present disclosure, a limited number of embodiments are illustrated in the drawings and are described with specific language in the following paragraphs. Nevertheless, no limitation of the scope of the disclosure is intended by describing only one or a limited number of embodiments. Any alterations and further modifications of the described embodiments, and any further applications of the principles of the invention as described herein, are contemplated as would normally occur to one skilled in the art to which the invention relates.

[0053] An exemplary insulated dunnage pad making apparatus 10 for making an insulated dunnage pad 12a is schematically depicted in FIGS. 1 A and 1 B. As shown in FIG. 1 A, the insulated dunnage pad making apparatus 10 includes a supply assembly 14 and a laminating assembly 16 downstream of the supply assembly 14 (as oriented by the downstream direction 18, the direction in which sheet material moves through the apparatus 10). The laminating assembly 16 is configured to selectively feed at least one layer of paper, such as expandable slit sheet material, from the supply assembly 14, expand the slit sheet material to an expanded state 20, and advance the slit sheet material in the expanded state 20 in the downstream direction.

[0054] The supply of slit sheet stock material includes a sheet stock material with one or more plies. The slit sheet material is supplied in one or more rolls. The slit sheet material in the roll may be wound about a hollow core that may be received on a respective supply support, such as an axle that rotates with the hollow core or about which the hollow core rotates as the sheet material is unwound off the roll.

[0055] Additionally or alternatively one or more plies of sheet material may be provided in another suitable arrangement, such as in a fan-folded stack (not shown), where the material is alternatingly folded into a stack of generally rectangular pages.

[0056] An exemplary sheet material is paper, such as kraft paper, and more particularly a single-ply kraft paper. Suitable kraft paper may have various basis weights, such as twenty-pound or forty-pound, for example. In some embodiments, the sheet material may be laminated or may include any other suitable material such as another paper, plastic sheets, metal foil, or any combination thereof.

[0057] An exemplary slit sheet material has a plurality of longitudinally-spaced, transversely-extending rows of slits periodically formed in the sheet. The slits in each row typically are transversely offset from respective slits in adjacent rows. More particularly, the exemplary slit sheet material is configured to expand along a feed direction, transverse the direction of the slits along the row. In other words, under tension across the slit the sheet material adjacent an upstream side of the slit separates from the sheet material adjacent a downstream side of the slit so that the sheet material separates across the slit. Tension typically is applied longitudinally, in the direction of advancement, the feed direction, also typically referred to as the downstream direction.

[0058] This exemplary slit sheet material is configured for expanding in one or more dimensions, also herein referred to as volume expansion or volumetric expansion. When the sheet material is stretched in a direction transverse the direction of the slits, perpendicular to a width dimension of the sheet material, the sheet material’s longitudinal length and its thickness increase, while the sheet material’s lateral width dimension decreases. The increased thickness as the sheet material is stretched longitudinally is caused at least in part by portions of the sheet material between the rows of slits rotating relative to the plane of the unexpanded sheet material. The thickness dimension extends in a normal direction relative to a face of the unexpanded sheet material. The normal direction is defined as generally orthogonal to the sheet material’s longitudinal length and also generally orthogonal to its width dimension, measured along a lateral extent between lateral edges of the sheet material.

[0059] The thickness of the slit sheet material can increase by an order of magnitude, or more, relative to its original thickness, when stretched in this manner. The expanded slit sheet material has an increased length and thickness and reduced width as compared to the unexpanded slit sheet material. This longitudinal stretching and increase in thickness results in a volumetrically-expanded expandable sheet material.

[0060] The laminating assembly 16 also is configured to feed two layers of cover sheet material 22a, 22b in the downstream direction 18 for laminating with the at least one layer of expandable slit sheet material in the expanded state 20 to form a continuous strip of insulated dunnage padding 24. Specifically, the laminating assembly 16 is configured to laminate the at least one layer of expandable slit sheet material in the expanded state 20 in between the two layers of cover sheet material 22a, 22b, as depicted.

[0061] Additionally, as shown in FIG. 1 B, the laminating assembly 16 may be configured to selectively feed at least two layers of expandable slit sheet material in the expanded state 20 in the downstream direction 18 from the supply assembly 14. The laminating assembly 16 also may be configured to selectively feed at least one layer of separator sheet material 23 in the downstream direction from the supply assembly 14 for lamination between two of the layers of expandable slit sheet material in the expanded state 20. That combination is further laminated between the two layers of cover sheet material 22a, 22b, to form the continuous strip of insulated dunnage padding 24. The laminating assembly 16 may be configured to laminate at least one layer of separator sheet material 23 in between each pair of layers of expandable slit sheet material in the expanded state 20, as depicted, to prevent nesting together of the at least two layers of expandable slit sheet material in the expanded state 20 in the continuous strip of insulated dunnage padding 24 and to minimize or restrict airflow between layers of expandable slit sheet material in the expanded state 20.

[0062] An exemplary insulated dunnage pad 12a formed by the insulated dunnage pad making apparatus 10 of FIGS. 1 A and 1 B is depicted in FIGS. 2A and 2B. The exemplary insulated dunnage pad 12a includes four layers of expandable slit sheet material in the expanded state 20 and three layers of separator sheet material 23, alternately laminated in between respective pairs of the expandable slit sheet material in the expanded state 20. This combination is further laminated between the layers of cover sheet material 22a, 22b to form the insulated dunnage pad 12a. The insulated dunnage pad 12a depicted in FIGS. 2A and 2B is provided as a non-limiting example and that other insulated dunnage pads 12a, having a different number of layers of expandable slit sheet material in the expanded state 20 and layers of separator sheet material 23 alternately laminated in between layers of the expandable slit sheet material in the expanded state, and further laminated between the two layers of cover sheet material 22a, 22b.

[0063] Another embodiment of the automated insulated dunnage pad making apparatus 10 for making another exemplary insulated dunnage pad 12b is schematically illustrated in FIGS. 3A and 3B. As shown in FIG. 3A, the laminating assembly 16 is configured to selectively feed at least one layer of expandable slit sheet material in an expanded state 20 and at least one layer of wadding material 25 in the downstream direction from the supply assembly 14. The wadding material 25 is a crumpled, embossed, or creped sheet material; typically has multiple layers; and those layers may be glued or otherwise secured together. The wadding material 25 generally is not slit. The laminating assembly 16 is also configured to feed two layers of cover sheet material 22a, 22b in the downstream direction 18 for laminating with the at least one layer of expandable slit sheet material in the expanded state 20 and the at least one layer of wadding material 25 to form a continuous strip of insulated dunnage padding 24. Specifically, the laminating assembly 16 is configured to laminate the at least one layer of expandable slit sheet material in the expanded state 20 and the at least one layer of wadding material 25 in between the two layers of cover sheet material 22a, 22b, as depicted.

[0064] As shown in FIG. 3B, the laminating assembly 16 may be configured to selectively feed at least two layers of expandable slit sheet material in the expanded state 20 in the downstream direction from the supply assembly 14, on one or both sides of the at least one layer of wadding material 25. In the depicted embodiment, at least two layers of expandable slit sheet material in the expanded state 20 are fed from the supply assembly 14 on both sides of the at least one layer of wadding material 25, however, there may only be at least two layers of expandable slit sheet material in the expanded state 20 on one side of the at least one layer of wadding material 25. The laminating assembly 16 may therefore also be configured to selectively feed at least one layer of separator sheet material 23 in the downstream direction from the supply assembly 14 for lamination with the at least two layers of expandable slit sheet material in the expanded state 20 and the at least one layer of wadding material 25, all between the two layers of cover sheet material 22a, 22b, to form the continuous strip of insulated dunnage padding 24. Specifically, the laminating assembly 16 may be configured to laminate the at least one layer of separator sheet material 23 in between each of the at least two layers of expandable slit sheet material in the expanded state 20, on one or both sides of the at least one layer of wadding material 25, to prevent nesting together of the at least two layers of expandable slit sheet material in the expanded state 20 in the continuous strip of insulated dunnage padding 24.

[0065] An exemplary insulated dunnage pad 12b formed by the insulated dunnage pad making apparatus 10 of FIGS. 3A and 3B is depicted in FIGS. 4A to 40. The insulated dunnage pad 12b includes two layers of expandable slit sheet material in the expanded state 20 on both sides of three layers of wadding material 25, and at least one layer of separator sheet material 23 laminated in between each of the two layers of expandable slit sheet material in the expanded state 20 on either side of the at least one layer of wadding material 25. Each of the at least two layers of expandable slit sheet material in the expanded state 20, the at least one layer of separator sheet material 23, and the at least one layer of wadding material 25 are laminated in between the two layers of cover sheet material 22a, 22b. It will be understood that the insulated dunnage pad 12b depicted in FIGS. 4A -4G is provided as a non-limiting example and that other insulated dunnage pads 12b, having a different number of layers of expandable slit sheet material in the expanded state 20, layers of separator sheet material 23, and layers of wadding material 25 laminated in between the two layers of cover sheet material 22a, 22b, may be formed by the insulated dunnage pad making apparatus 10 described herein.

[0066] Turning back to FIGS. 1 A, 1 B, 3A, and 3B, in any embodiment, the insulated dunnage pad making apparatus 10 may also include a cutting assembly 26 downstream of the laminating assembly 16. The cutting assembly 26 is configured to cut the continuous strip of insulated dunnage padding 24 along a direction perpendicular to the downstream direction 18 to form the respective insulated dunnage pad 12a, 12b.

[0067] The insulated dunnage pad making apparatus 10 also includes a controller 28 for generally coordinating and controlling the operation of the insulated dunnage pad making apparatus 10 and each of its component parts, described in detail below. The controller 28 may include a processor, a memory, and a program stored in the memory. The controller 28 may additionally include one or more input devices, such as for determining the desired length, composition and number of layers of each material of the desired resultant insulated dunnage pad 12a, 12b, and one or more outputs, including outputs for controlling elements of the insulated dunnage pad making apparatus 10. The input devices can be connected to or include one or more of a touch screen display, a keyboard, a mouse, a scanner or sensor, a bar code reader, a radio frequency identification device (RFID) sensor, a microphone, a camera, etc. The controller 28 can be programmed to recognize the appropriate inputs that represent a desired length of the insulated dunnage pad 12a, 12b or identify a location to look up one or more available lengths.

[0068] The insulated dunnage pad 12a, 12b may have a width in the range of approximately 20.32 centimeters (8 inches) to 45.72 centimeters (18 inches). The various layers of sheet material 20, 23, 25, 22a, 22b of the insulated dunnage pad 12a, 12b preferably include or are made of paper, particularly kraft paper, making the insulated dunnage pad 12a, 12b recyclable, reusable, and composed of a renewable resource. The layers of sheet material 20, 23, 25, 22a, 22b, may all be made of the same or different materials and may have the same basis weights or different basis weights. For example, each of the at least one layer of wadding material 25 may be a very light basis weight (e.g., 7 pound) crepe paper that is stacked to twenty-two layers thick, making the at least one layer of wadding material 25 approximately 1 .27 centimeters (0.5 inches) thick. The at least one layer of separator sheet material 23 may have a basis weight of 15 pounds. The two layers of cover sheet material 22a, 22b may have the same dimensions as each other and may have a coating material included thereon to create a water and / or water vapor barrier sufficient to make the cover sheet material water resistant or waterproof. The at least one layer of expandable slit sheet material 20, the at least one layer of separator sheet material 23, and the at least one layer of wadding material 25 may each have different width and thickness dimensions in comparison to those dimensions of the two layers of cover sheet material 22a, 22b, and in comparison to each other. For example, the at least one layer of expandable slit sheet material in the expanded state 20 may be narrower in width and thicker than the two layers of cover sheet material 22a, 22b.

[0069] With reference to FIGS. 5-15, the insulated dunnage pad making apparatus 10 for making the insulated dunnage pad 12a, 12b will be described in more detail. As depicted in FIGS. 5-8, the supply assembly 14 includes two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d, each configured to support a roll of expandable slit sheet material 32a, 32b, 32c, 32d that is used to form the one or more layers of expandable slit sheet material in the expanded state 20. In the depicted embodiments, for example, the supply assembly 14 includes four expandable slit sheet material supply supports 30a, 30b, 30c, 30d, each configured to support a respective roll of expandable slit sheet material 32a, 32b, 32c, 32d. It will be understood, however, that the supply assembly 14 may alternatively include a different number of expandable slit sheet material supply supports 30a, 30b, 30c, 30d, each configured to support a respective roll of expandable slit sheet material 32a, 32b, 32c, 32d.

[0070] Each of the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d may be in the form of spindles rotatably mounted to a frame 15a of the supply assembly 14. Each of the spindles of the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d may be supported on the frame 15a such that they are configured to apply a constant tension on the respective roll of expandable slit sheet material 32a, 32b, 32c, 32d to reduce rotational speed and minimize or prevent overtravel of the expandable slit sheet material being fed therefrom. The two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d also may include disc brakes attached to the supports 30a, 30b, 30c, 30d to stop the rotation of the respective roll of expandable slit sheet material 32a, 32b, 32c, 32d and prevent any unwinding or bagging that may occur whenever the feeding operation stops.

[0071] In the embodiment shown in FIGS. 5 and 6, the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d are each mounted to the frame 15a above a feed track 17 of the supply assembly 14, on which the expandable slit sheet material pulled from each respective roll of expandable slit sheet material 32a, 32b, 32c, 32d is guided in the downstream direction 18 toward the laminating assembly 16. Alternatively, the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d may alternatively be mounted to the frame 15a below the feed track 17. In the embodiment depicted in FIGS. 7 and 8, at least one of the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d is mounted to the frame 15a above the feed track 17, and at least another one of the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d is mounted to the frame 15b below the feed track 17.

[0072] The supply assembly 14 also may include at least two expanders 34a, 34b, 34c, 34d, each positioned adjacent a respective one of the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d. Each of the at least two expanders 34a, 34b, 34c, 34d are configured to pull expandable slit sheet material from the respective adjacent roll of expandable slit sheet material 32a, 32b, 32c, 32d in the downstream direction, and in doing so, expand the expandable slit sheet material from an unexpanded state (as provided on the roll of expandable slit sheet material 32a, 32b, 32c, 32d) to the expanded state (as received and fed by the laminating assembly 16). In the embodiments depicted in FIGS. 5-8, for example, the supply assembly 14 includes four expanders 34a, 34b, 34c, 34d, each positioned adjacent a respective one of the four depicted expandable slit sheet material supply supports 30a, 30b, 30c, 30d. It will be understood, however, that the supply assembly 14 may alternatively include a different number of expanders 34a, 34b, 34c, 34d, each positioned adjacent a respective expandable slit sheet material supply support 30a, 30b, 30c, 30d.

[0073] Each of the at least two expanders 34a, 34b, 34c, 34d may be mounted to the frame 15a of the supply assembly 14. In the embodiment depicted in FIGS. 5 and 6, the at least two expanders 34a, 34b, 34c, 34d are each mounted to the frame 15a above the feed track 17, adjacent each of the expandable slit sheet material supply supports 30a, 30b, 30c, 30d. Alternatively, for example when the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d are each mounted to the frame 15a below the feed track 17, the at least two expanders 34a, 34b, 34c, 34d also may be mounted to the frame 15a below the feed track 17. In the embodiment depicted in FIGS. 7 and 8, at least one of the at least two expanders 34a, 34b, 34c, 34d is mounted to the frame 15a above the feed track 17, and at least another one of the at least two expanders 34a, 34b, 34c, 34d is mounted to the frame 15b below the feed track 17.

[0074] Turning to FIG. 9, to expand the expandable slit sheet material from the unexpanded state to the expanded state, each of the at least two expanders 34a, 34b, 34c, 34d may include an upstream pair of expanding rollers 35a and a downstream pair of expanding rollers 35b downstream of the upstream pair of expanding rollers 35a. The upstream pair of expanding rollers 35a are configured to draw the expandable slit sheet material from a respective roll of expandable slit sheet material 32a, 32b, 32c, 32d and feed the expandable slit sheet material in the downstream direction 18 at a first speed. The downstream pair of expanding rollers 35b are configured to feed the expandable slit sheet material in the downstream direction 18 at a second speed. The second speed may be faster than the first speed, such that as the downstream pair of expanding rollers 35b feed the expandable slit sheet material in the downstream direction 18 a stretching tension is applied to the expandable slit sheet material. This stretching tension causes the expandable slit sheet material to stretch from the unexpanded state to the expanded state, with the slits opening and the material adjacent the slits rotating out of its formerly-planar state. This provides the expandable slit sheet material in the expanded state that is longer, thicker, and narrower than the expandable slit-sheet material in the unexpanded state.

[0075] As each of the at least two expanders 34a, 34b, 34c, 34d expands the expandable slit sheet material to the expanded state, the expandable slit sheet material inelastically deforms. This deformation causes the expandable slit sheet material to remain in the expanded state and decreases any tendency of the expandable slit sheet material to return to its previous unexpanded state. The expanded slit sheet material may relax slightly to an unstressed, yet expanded, state after being expanded by each of the at least two expanders 34a, 34b, 34c, 34d.

[0076] In an alternative embodiment, the at least two expanders 34a, 34b, 34c, 34d may be omitted and the expandable slit sheet material may be provided in an already-expanded form from a supply, such as a roll, of expanded expandable slit sheet material. Using the at least two expanders 34a, 34b, 34c, 34d, however, allows for more compact rolls of expandable slit sheet material 32a, 32b, 32c, 32d of a given length in comparison to rolls of an equivalent length of expanded slit sheet material.

[0077] Turning back to FIGS. 5-8, the supply assembly 14 further includes at least one separator sheet material supply supports 40a, 40b, 40c, each configured to support a respective roll of separator sheet material 42a, 42b, 42c that is used to form the one or more layer of separator sheet material 23 for separating two or more layers of expandable slit sheet material 20 in the insulated dunnage pad 12a, 12b. In the embodiment depicted in FIGS. 5 and 6, in which the supply assembly 14 includes four expandable slit sheet material supply supports 30a, 30b, 30c, 30d, all mounted to the frame 15a above the feed track 17, the supply assembly 14 includes three separator sheet material supply supports 40a, 40b, 40c, also mounted to the frame 15a above the feed track 17.

[0078] It will be understood, however, that the supply assembly 14 may alternatively include a different number of separator sheet material supply supports 40a, 40b, 40c, depending on the number of expandable slit sheet material supply supports 30a, 30b, 30c, 30d, and where they are mounted. For example, in the embodiment depicted in FIGS. 7 and 8, in which the supply assembly 14 includes four expandable slit sheet material supply supports 30a, 30b, 30c, 30d with two mounted to the frame 15a above the feed track 17 and two mounted to the frame 15a below the feed track 17, the supply assembly 14 includes two separator sheet material supply supports 40a, 40b. One may be mounted above the feed track 17 for forming at least one layer of separator sheet material 23 for separating the at least two layers of expandable slit sheet material 20 pulled from the two expandable slit sheet material supply supports 30a, 30b mounted above the feed track 17, and one may be mounted below the feed track 17 for forming at least one layer of separator sheet material 23 for separating the at least two layers of expandable slit sheet material 20 pulled from the two expandable slit sheet material supply supports 30c, 30d mounted below the feed track 17.

[0079] Each of the one or more separator sheet material supply supports 40a, 40b, 40c may be in the form of fixed or rotatable spindles mounted to the frame 15a of the supply assembly 14. In the depicted embodiment, the one or more separator sheet material supply supports 40a, 40b, 40c are each mounted to the frame 15a above the feed track 17 of the supply assembly 14. In another embodiment, the one or more separator sheet material supply supports 40a, 40b, 40c may alternatively be mounted to the frame 15a below the feed track 17.

[0080] In the embodiment depicted in FIG. 7, the supply assembly 14 may additionally or alternatively include at least one wadding material supply support 29a, 29b, 29c, 29d, 29e, 29f, each configured to support a roll of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f. When the supply assembly 14 includes more than one wadding material supply support 29a, 29b, 29c, 29d, 29e, 29f, only some of the more than one wadding material supply support 29a, 29b, 29c, 29d, 29e, 29f, may be used to support a respective roll of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f that is used to form at least one layer of wadding material 25 (as depicted in the insulated dunnage pad 12b of FIGS. 3A-4B), while the other(s) of the more than one wadding material supply support 29a, 29b, 29c, 29d, 29e, 29f, may be used to support backup or spare roll (s) of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f. For example, in the depicted embodiment of FIG. 7, the supply assembly 14 includes six wadding material supply supports 29a, 29b, 29c, 29d, 29e, 29f, each configured to support a respective roll of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f. Three of the six wadding material supply supports 29a, 29b, 29c, are mounted above the feed track 17 to support three rolls of wadding material 31 a, 31 b, 31 c used to form the at least one layer of wadding material 25, while the other three of the six wadding material supply supports 29d, 29e, 29f are mounted below the feed track 17 to support three backup or spare rolls of wadding material 31 d, 31 e, 31 f. It will be understood, however, that the supply assembly 14 may alternatively include a different number of wadding material supply supports 29a, 29b, 29c, 29d, 29e, 29f, and that the wadding material supply supports 29a, 29b, 29c, 29d, 29e, 29f may be mounted either above or below the feed track 17. Each of the at least one wadding material supply support 29a, 29b, 29c, 29d, 29e, 29f may be in the form of spindles rotatably mounted to the frame 15a of the supply assembly 14. The at least one layer of wadding material 25 also may function as a separator sheet as a substitute for the layer of separator sheet material 23.

[0081] As depicted in FIGS. 5 and 6, the frame 15a of the supply assembly 14 may be mounted on wheels 19a so that it is easily movable relative to the laminating assembly 16, for example, for restocking the two or more rolls of expandable slit sheet material 32a, 32b, 32c, 32d, the one or more rolls of separator sheet material 42a, 42b, 42c, or the one or more rolls of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f, or for maintenance of any of the various parts of the supply assembly 14. Alternatively, as depicted in FIGS. 7 and 8, the frame 15a of the supply assembly 14 may be mounted on feet 9. The feed track 17 may be width adjustable, for example, to accommodate various widths of respective material on each roll of expandable slit sheet material 32a, 32b, 32c, 32d, each roll of separator sheet material 42a, 42b, 42c, and each roll of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f. The frame 15b of the laminating assembly 16 also may be mounted on wheels 19b so that it is easily movable relative to the supply assembly 14, for example, for restocking of the two or more rolls of cover sheet material 22a, 22b, or for maintenance of any of the various parts of the laminating assembly 16. Alternatively, the frame 15b of the laminating assembly 16 may be mounted on feet. As depicted in FIG. 5, 7 and 10, the laminating assembly 16 includes two cover sheet material supply supports 36a, 36b, each configured to support a roll of cover sheet material 38a, 38b that is used to form the two layers of cover sheet material 22a, 22b. Specifically, the two cover sheet material supports 36a, 36b include a top cover sheet material support 36a configured to support a roll of top cover sheet material 38a for forming the top layer of cover sheet material 22a, and a bottom cover sheet material support 36b configured to support a roll of bottom cover sheet material 38b for forming a bottom layer of cover sheet material 22b. Each of the two cover sheet material supply supports 36a, 36b may be in the form of spindles rotatably mounted to a frame 15b of the laminating assembly 16. As depicted, the top cover sheet material support 36a is mounted to the frame 15b above a feed path 21 , along which the at least one layer of expandable slit sheet material 20, the at least one layer of separator sheet material 23, and the at least one layer of wadding material 25 enter and travel through the laminating assembly 16, and the bottom cover sheet material support 36b is mounted to the frame 15b below the feed path 21.

[0082] Turning to FIGS. 11 -13, the laminating assembly 16 includes an adhesive applicator assembly 44, a compression roller assembly 50 downstream of the adhesive applicator assembly 44, and a conveyor assembly 58 downstream of the compression roller assembly 50. The adhesive applicator assembly 44 is depicted in FIGS. 11 and 12 adjacent to and downstream of the compression roller assembly 50. The conveyor assembly 58 is depicted in isolation in FIG. 13.

[0083] The adhesive applicator assembly 44 is configured to deposit an adhesive to an upper surface of the bottom layer of cover sheet material 22b pulled from the bottom roll of cover sheet material 38b and / or an upper surface of the at least one layer of expandable slit sheet material in the expanded state 20 pulled from the supply assembly 14, adjacent opposing lateral edges thereof. Any of the adhesive applied to opposing lateral edges of the at least one layer of expandable slit sheet material in the expanded state 20 will pass through the opened slits to reach the upper surface of the bottom layer of cover sheet material 22b. If the at least one layer of expandable slit sheet material in the expanded state 20 has a narrower width than the bottom layer of cover sheet material 22b, the adhesive applied by the adhesive applicator assembly 44 will be applied directly to the upper surface of the bottom layer of cover sheet material 22b, that is, without having to pass through the slits in the at least one layer of expandable slit sheet material in the expanded state 20.

[0084] Specifically, the adhesive applicator assembly 44 may include at least two adhesive heads 46, in the illustrated embodiment two hot glue heads, respectively mounted to the adhesive applicator assembly 44 at opposite lateral sides of a cross bar 48 extending across the feed path 21 . The adhesive heads 46 are positionable so as to be aligned with respective lateral edges of the bottom layer of cover sheet material 22b above the feed path 21 at a sufficient height to allow passage of the bottom layer of cover sheet material 22b, two or more layers of expandable slit sheet material in the expanded state 20 and one or more layer of separator sheet material 23. The two adhesive heads 46 may be movable in the lateral direction along the cross bar 48 to accommodate for different widths of the bottom layer of cover sheet material 22b, so as to be aligned with lateral edges of the bottom layer of cover sheet material 22b. In one form, the adhesive heads 46 may be activated by means of respective pneumatic solenoid valves integrated in the structure of the adhesive heads 46.

[0085] Once the adhesive is deposited by the adhesive applicator assembly 44, the compression roller assembly 50 compresses the bottom layer of cover sheet material 22b, the at least one layer of expandable slit sheet material in the expanded state 20, the at least one layer of separator sheet material 23 (if present), and the at least one layer of wadding material 25 (if present) for lamination with the top layer of cover sheet material 22a. As best depicted in FIG. 12, the compression roller assembly 50 may therefore include a pair of compression rollers 52a, 52b, including a top compression roller 52a and a bottom compression roller 52b, configured to compress the layers 22a, 22b, 20, 23, and 25 and seal the edges of the top and bottom layers of cover sheet material 22a and 22b. The compression roller assembly 50 may include a top cover sheet guide roller 54 for guiding the top layer of cover sheet material 22a from the roll of top cover sheet material 38a toward the pair of compression rollers 52a, 52b.

[0086] Each compression roller 52a, 52b may include a pair of compression collars 56 that are laterally adjustable along the compression roller 52a, 52b to accommodate different widths of the top and bottom layers of cover sheet material 22a, 22b, so as to be aligned with respective lateral edges of the top and bottom layers of cover sheet material 22a, 22b. The pair of compression rollers 52a, 52b and their respective compression collars 56 may be made of aluminum. The pair of compression rollers 52a, 52b are biased (e.g., spring loaded) toward each other to compress the top layer of cover sheet material 22a and the bottom layer of cover sheet material 22b together with the at least one layer of expandable slit sheet material in the expanded state 20, the at least one layer of separator sheet material 23 (if present), and the at least one layer of wadding material 25 (if present) secured therebetween. The pair of compression rollers 52a, 52b, however, may include a quick release mechanism for releasing the bias for loading materials. The compression roller assembly 50 therefore not only aids in feeding the various materials through the laminating assembly 16, but also laminates the various materials together to form the continuous strip of insulated padding 24.

[0087] Once the various layers 22a, 22b, 20, 23, 25 are laminated and bonded together, sealing the edges to form the continuous strip of insulated padding 24, the continuous strip of insulated padding 24 is pulled in the downstream direction 18 by the conveyor assembly 58. As depicted in FIG. 13, the conveyor assembly 58 includes a top conveyor 60a and a bottom conveyor 60b. The top conveyor 60a and / or the bottom conveyor 60b may include one or more segments, widthwise across the feed path 21 and / or sequentially along the feed path 21 . The width of the top and bottom conveyors 60a, 60b may be adjusted to match or be greater than the width of the continuous strip of insulated padding 24 to maintain grip on the entire width of the materials. The top and bottom conveyors 60a, 60b may be mounted to the frame 15b of the laminating assembly 16. At least the top conveyor 60a may be mounted to the frame 15b in a way that allows it to move upward and downward relative to the bottom conveyor 60b to accommodate different thicknesses of the continuous strip of insulated padding 24 (e.g., different number of layers of expandable slit sheet material in the expanded state 20, layers of separator sheet material 23, and layers of wadding material 25 secured therein), while still using its weight to compress and grip the continuous strip of insulated padding 24. The compression load can be changed to control the amount of grip and prevent excessive compression that might pierce the separating layers and reduce thermal or cushioning effectiveness. As shown in FIG. 13, a pneumatic cylinder 65 may be used to control the spacing between the top conveyor 60a and the bottom conveyor 60b and the pressure applied therebetween.

[0088] The top conveyor 60a has a top drive belt 62a and the bottom conveyor 60b has a bottom drive belt 62b. The top and bottom drive belts 62a, 62b are configured to frictionally engage respective upper and lower surfaces of the continuous strip of insulated padding 24 to drive the continuous strip of insulated padding 24 through the conveyor assembly 58. The position or spacing, and the weight of the top conveyor 60a are provided to create a gap between the top and bottom drive belts 62a, 62b to be slightly smaller than the thickness of the continuous strip of insulated padding 24 so that the top and bottom conveyors 60a, 60b slightly compress the continuous strip of insulated padding 24 as it is driven by the top and bottom drive belts 62a, 62b. The top and bottom drive belts 62a, 62b may be driven in any suitable manner. For example, in the illustrative example, the top conveyor 60a includes a top series of rollers 64a that, in side elevational view, drive the top drive belt 62a counterclockwise and the bottom conveyor 60b includes a bottom series of rollers 64b that, in side elevational view, drive the bottom drive belt 62b clockwise to feed the insulated padding along the feed path 21 . A motor (not shown), such as a servo motor, may be coupled to the respective rollers 64a, 64b to drive the rollers 64a, 64b.

[0089] The upstream end of the top and bottom conveyors 60a, 60b may be tapered to define a narrowing channel 66 at an inlet. Downstream from the narrowing channel 66, the lower surface of the top drive belt 62a and the upper surface of the bottom drive belt 62b define a feeding channel 68, aligned with the feed path 21 of the continuous strip of insulated padding 24 through the conveyor assembly 58. In this way, the narrowing channel 66 may be configured to guide the continuous strip of insulated padding 24 into the feeding channel 68 and along the feed path 21 . The height of the feeding channel 68, that is the height between the lower surface of the top drive belt 62a and the upper surface of the bottom drive belt 62b, is such that the top and bottom drive belts 62a, 62b squeeze the continuous strip of insulated padding 24 therebetween to enable the first and second conveyor 60a, 60b to frictionally engage and thus drive the continuous strip of insulated padding 24 in the downstream direction 18.

[0090] The length of engagement of the top and bottom drive belts 62a, 62b with the respective upper and lower surfaces of the continuous strip of insulated padding 24 is selected to prevent or minimize crumpling or tearing of the continuous strip of insulated padding 24 as the first and second conveyors 60a, 60b drive the continuous strip of insulated padding 24 through the conveyor assembly 58. To that end, the top and bottom drive belts 62a, 62b may be configured to engage the continuous strip of insulated padding 24 along the lateral edges where the material layers 22a, 22b, 20, 23, 25 have already been compressed. The at least one layer of expandable slit sheet material in the expanded state 20 is sufficiently resilient, however, to enable the top and bottom drive belts 62a, 62b to slightly compress the continuous strip of insulated padding 24 without decreasing the cushioning or thermal properties of the continuous strip of insulated padding 24.

[0091] Downstream of the laminating assembly 44, that is, downstream of the compression roller assembly 50, the insulated dunnage pad making apparatus 10 may additionally include the cutting assembly 26. The cutting assembly 26 may be mounted to the frame 15b of the laminating assembly 16, as depicted in FIGS. 5 and 10, or may be provided separately, for example mounted on a pad conveyor 76 downstream of the laminating assembly 16, as depicted in FIG. 15. The cutting assembly 26 is depicted in isolation in FIGS. 14A -14C. The illustrated cutting assembly 26 includes a motor 70 and dual linkages 72 that drive a cutting blade 74 (FIG. 14C) to cut the continuous strip of insulated padding 24 to form a discrete insulated dunnage pad 12a, 12b (FIGS. 1 and 3). The cutting operation occurs in two stages. First a press bar 75 moves downward to capture the strip of insulated padding and compress a portion of the strip against a landing 77 adjacent a lower cutting blade 73 (see FIG. 14B) and compresses the strip. Then the cutting blade 74 is driven downward and cooperates with the lower cutting blade 73 to sever a discrete insulated dunnage pad from the strip. Compressing the strip of insulated padding before cutting creates a thinner profile of the continuous strip of insulated padding 24 close to where the cutting blade 74 is to cut the continuous strip of insulated padding 24 and holds the strip and keeps it from shifting, resulting in a cleaner cut without tearing.

[0092] The motor 70 may be any suitable motor, for example, a 48VDC motor. The motor 70 makes one complete rotation in cutting the continuous strip of insulated padding 24 and returning the cutting blade 74 to its retracted, or home, position. The cutting assembly 26 is equipped with a home sensor to confirm the cutting blade 74 has returned to its retracted position. The cutting assembly 26 may be configured to cut the continuous strip of insulated padding 24 on-the-fly, that is simultaneously as the laminating assembly 16 is in operation. For example, the illustrated cutting assembly 26 may translate longitudinally at the same speed as the continuous strip of insulated padding 24 to cut without stopping movement of the continuous strip of insulated padding 24 in the downstream direction 18, or the cutting assembly 26 may be formed by a rotating element with the cutting blade 74. Alternatively, the laminating assembly 16 may be stopped or temporarily paused as the cutting assembly 26 cuts the continuous strip of insulated padding 24.

[0093] With reference to FIG. 15, the insulated dunnage pad making apparatus 10 may further include an exit conveyor assembly 76 downstream of the cutting assembly 26 and aligned with the flow path 21 of the laminating assembly 16 for conveying the insulated dunnage pads 12a, 12b in the downstream direction 18 after being cut by the cutting assembly 26. The exit conveyor assembly 76 includes an exit conveyor belt 78 configured to carry the insulated dunnage pads 12a, 12b in the downstream direction. The exit conveyor belt 78 may be width adjustable, for example, to accommodate various widths of insulated dunnage pads 12a, 12b. The exit conveyor assembly 76 may additionally include a cutting guard 80 configured to shield the cutting assembly 26. The exit conveyor belt 78 and the cutting guard 80 may be mounted to a frame 15c of the exit conveyor assembly 76.

[0094] The exit conveyor assembly 76 may also include a creasing assembly (not shown) for creasing the insulated dunnage pad 12a, 12b at predetermined locations along the downstream direction 18 to allow for easier bending or folding when inserting the insulated dunnage pads 12a, 12b into a box or other container.

[0095] The insulated dunnage pad making apparatus 10, therefore, allows an operator to form an insulated dunnage pad 12a, 12b having cushioning, wrapping, and thermal insulation properties tailored to any specific application for optimal performance. That is, an operator can variably select any number and combination of layers of expandable slit sheet material in the expanded state 20, separator sheet material 23 and / or wadding material 25 for lamination between two layers of cover sheet material 22a, 22b. This flexibility allows for a resultant insulated dunnage pad 12a, 12b that is customized for thickness, thermal performance, and cost.

[0096] A method of making an insulated dunnage pad, such as the insulated dunnage pad 12a, 12b described above, may be performed using the insulated dunnage pad making apparatus 10 described fully above. That is, the method includes a step of selectively feeding at least one layer of expandable slit sheet material in an expanded state in a downstream direction from at least one of two or more supplies of expandable slit sheet material. For example, the two or more supplies of expandable slit sheet material may be the two or more expandable slit sheet material supply supports 30a, 30b, 30c, 30d, each supporting the respective roll of expandable slit sheet material 32a, 32b, 32c, 32d, described above. The step of selectively feeding the at least one layer of expandable slit sheet material in the expanded state may include expanding at least one layer of expandable slit sheet material in an unexpanded state to an expanded state, with for example, at least one of the at least two expanders 34a, 34b, 34c, 34d described above. The method also includes a step of feeding two layers of cover sheet material in the downstream direction from two supplies of cover sheet material. For example, the two supplies of cover sheet material may be the two cover sheet material supply supports 36a, 36b, each supporting the respective roll of cover sheet material 38a, 38b, described above.

[0097] In an embodiment in which the method includes selectively feeding at least two layers of expandable slit sheet material in the expanded state in the downstream direction from the two or more supplies of expandable slit sheet material, the method also includes a step of selectively feeding at least one layer of separator sheet material in the downstream direction from one or more supply of separator sheet material. The one or more supply of separator sheet material may be the one or more separator sheet material supply supports 40a, 40b, 40c, each supporting a roll of separator sheet material 42a, 42b, 42c, described above. The method may also include a step of selectively feeding at least one layer of wadding material in the downstream direction from at least one supply of wadding material. For example, the at least one supply of wadding material may be the at least one wadding material supply support 29a, 29b, 29c, 29d, 29e, 29f, each configured to support a roll of wadding material 31 a, 31 b, 31 c, 31 d, 31 e, 31 f, described above.

[0098] The method then includes a step of laminating the at least one layer of expandable slit sheet material in the expanded state (and the at least one layer of separator material alone and / or in combination with the at least one layer of wadding material) in between the two layers of cover sheet material to form a continuous strip of insulated dunnage padding, such as the continuous strip of insulated padding 24, described above. In the embodiment in which the method includes selectively feeding at least two layers of expandable slit sheet material in the expanded state and at least one layer of separator sheet material in the downstream direction, the method further includes laminating the at least one layer of separator sheet material in between each of the at least two layers of expandable slit sheet material in the expanded state. In the embodiment in which the method includes selectively feeding the at least one layer of wadding material, the method further includes laminating the at least one layer of wadding material and the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material.

[0099] The step of laminating the at least one layer of expandable slit sheet material in the expanded state (and the at least one layer of separator material and / or the at least one layer of wadding material, when present) in between the two layers of cover sheet material to form a continuous strip of insulated padding may include depositing an adhesive on opposing lateral edges of an upper surface of a bottom layer of cover sheet material of the two layers of cover sheet material. For example, this step may be accomplished with the adhesive applicator assembly 44 of the laminating assembly 16, described above. Additionally, the step of laminating the at least one layer of expandable slit sheet material in the expanded state (and the at least one layer of separator material and / or the at least one layer of wadding material, when present) in between the two layers of cover sheet material to form a continuous strip of insulated padding may further include compressing opposing lateral edges of the two layers of cover sheet material together to seal the at least one layer of expandable slit sheet material in the expanded state (and the at least one layer of separator material and / or the at least one layer of wadding material, when present) therebetween. This step may be accomplished with the compression roller assembly 50 of the laminating assembly 16, described above. Finally, the step of laminating the at least one layer of expandable slit sheet material in the expanded state (and the at least one layer of separator material and / or the at least one layer of wadding material, when present) in between the two layers of cover sheet material to form a continuous strip of insulated padding may also include conveying the continuous strip of insulated padding in the downstream direction toward the cutting assembly. This may be accomplished with the conveyor assembly 58 described above.

[0100] The method finally includes cutting the continuous strip of insulated dunnage padding along a direction perpendicular to the downstream direction to form the insulated dunnage pad. For example, the step of cutting may be accomplished by the cutting assembly 26 described above. The method may then further include a step of conveying the insulated dunnage pad, after the step of cutting, in the downstream direction with, for example, the exit conveyor assembly 76 described above. The method may also further include a step of creasing the insulated dunnage pad with, for example, the creasing assembly 82 described above, to allow for easier bending or folding when inserting the insulated dunnage pad into a box or other container.

[0101] All features disclosed herein, including the claims, abstract, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. Each feature disclosed herein, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise.

[0102] Although the invention defined by the following claims has been shown and described with respect to a certain embodiment, equivalent alternations and modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.

[0103] * * *

Claims

ClaimsWe claim:1 . An insulated dunnage pad making apparatus comprising: a supply assembly including: two or more expandable slit sheet material supply supports, each configured to support a respective roll of expandable slit sheet material; and a laminating assembly downstream of the supply assembly, the laminating assembly including: two cover sheet material supply supports, each configured to support a respective roll of cover sheet material; wherein the laminating assembly is configured to: selectively feed at least one layer of expandable slit sheet material in the expanded state in a downstream direction from the respective roll of expandable slit sheet material supported by at least one of the two or more expandable slit sheet material supply supports; feed two layers of cover sheet material in the downstream direction from the respective rolls of cover sheet material supported on each of the two cover sheet material supply supports; and laminate the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated dunnage padding for forming the insulated dunnage pad.

2. The insulated dunnage pad making apparatus according to claim 1 , further comprising one or more separator sheet material supply supports, each configured to support a respective roll of separator sheet material; wherein the laminating assembly is configured to selectively feed at least two layers of expandable slit sheet material in the expanded state in the downstreamdirection from the respective roll of expandable slit sheet material supported by at least two of the two or more expandable slit sheet material supply supports; selectively feed at least one layer of separator sheet material in the downstream direction from the respective roll of separator sheet material supported by the one or more separator sheet material supply supports; and laminate the at least one layer of separator sheet material in between each of the at least two layers of expandable slit sheet material.

3. The insulated dunnage pad making apparatus according to any one of claim 1 or claim 2, further comprising a cutting assembly downstream of the laminating assembly, the cutting assembly being configured to cut the continuous strip of insulated padding to form the insulated dunnage pad.

4. The insulated dunnage pad making apparatus according to any one of claim 1 to claim 3, wherein the supply assembly further includes at least two expanders, each positioned adjacent a respective one of the at least two expandable slit sheet material supply supports and each configured to pull expandable slit sheet material from the respective roll of expandable slit sheet material in the downstream direction and expand the expandable slit sheet material from an unexpanded state to an expanded state.

5. The insulated dunnage pad making apparatus according to any one of claim 1 to claim 4, wherein the laminating assembly further includes an adhesive applicator assembly configured to deposit an adhesive on an upper surface of a bottom layer of cover sheet material of the two layers of cover sheet material.

6. The insulated dunnage pad making apparatus according to any one of claim 1 to claim 5, wherein the laminating assembly further includes a compression roller assembly configured to compress lateral edges of the two layers of cover sheetmaterial together to seal the at least one layer of expandable slit sheet material therebetween.

7. The insulated dunnage pad making apparatus according to claim 6, wherein the compression roller assembly includes a pair of compression rollers, each having a pair of compression collars for compressing the lateral edges of the two layers of cover sheet material together to seal the at least one layer of expandable slit sheet material therebetween.

8. The insulated dunnage pad making apparatus according to any one of claim 1 to claim 7, wherein the laminating assembly further includes a conveyor assembly configured to convey the continuous strip of insulated padding in the downstream direction.

9. The insulated dunnage pad making apparatus according to claim 8, wherein the conveyor assembly includes a top conveyor having a top drive belt and a bottom conveyor having a bottom drive belt, the top and bottom drive belt configured to convey the continuous strip of insulated padding therebetween in the downstream direction.

10. The insulated dunnage pad making apparatus according to any one of claim 1 to claim 9, further comprising an exit conveyor assembly downstream of the laminating assembly for conveying the insulated dunnage pad.11 . The insulated dunnage pad making apparatus according to claim 10, wherein the exit conveyor assembly includes a creasing assembly for creasing the insulated dunnage pad.

12. A method of making an insulated dunnage pad comprising the steps of: selectively feeding at least one layer of expandable slit sheet material in an expanded state in a downstream direction from at least one of two or more supplies of expandable slit sheet material; feeding two layers of cover sheet material in the downstream direction from two supplies of cover sheet material; laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding; and cutting the continuous strip of insulated padding along a direction perpendicular to the downstream direction to form the insulated dunnage pad.

13. The method according to claim 12, wherein the step of selectively feeding the at least one layer of expandable slit sheet material in the expanded state includes selectively feeding at least two layers of expandable slit sheet material in the expanded state in the downstream direction from at least two of the two or more supplies of expandable slit sheet material, the method further including the step of selectively feeding at least one layer of separator sheet material in the downstream direction from at least one supply of separator sheet material.

14. The method according to claim 13, wherein the method further includes the step of laminating the at least one layer of separator sheet material in between each of the at least two layers of expandable slit sheet material in the expanded state.

15. The method according to any one of claim 12 to claim 14, wherein the step of selectively feeding the at least one layer of expandable slit sheet material in the expanded state includes expanding at least one layer of expandable slit sheet material in an unexpanded state to an expanded state.

16. The method according to any one of claim 12 to claim 15, wherein the step of laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding includes depositing an adhesive on opposing lateral edges of an upper surface of a bottom layer of cover sheet material of the two layers of cover sheet material.

17. The method according to claim 16, wherein the step of laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding further includes compressing opposing lateral edges of the two layers of cover sheet material together to seal the at least one layer of expandable slit sheet material in the expanded state therebetween.

18. The method according to any one of claim 12 to claim 17, wherein the step of laminating the at least one layer of expandable slit sheet material in the expanded state in between the two layers of cover sheet material to form a continuous strip of insulated padding includes conveying the continuous strip of insulated padding in the downstream direction toward the cutting assembly.

19. The method according to any one of claim 12 to claim 18, further including conveying the insulated dunnage pad in the downstream direction.

20. The method according to any one of claim 12 to claim 19, further including creasing the insulated dunnage pad.

Images