CA1072795A

CA1072795A - Cushioning dunnage mechanism, transfer cart therefor, and method

Info

Publication number: CA1072795A
Application number: CA249,665A
Authority: CA
Inventors: Gary W. Ottaviano
Original assignee: Ranpak Corp
Current assignee: Ranpak Corp
Priority date: 1975-05-01
Filing date: 1976-04-06
Publication date: 1980-03-04
Also published as: US4085662A; US4109040A; US4026198A

Abstract

CUSHIONING DUNNAGE MECHANISM, TRANSFER CART THEREFOR, AND METHOD A cushioning dunnage producing mechanism which is of relatively compact nature utilizing a single multi-ply roll of sheet-like stock material, such as paper, which is directed through a separating mechanism. As the stock is pulled off the composite roll, the edges are rolled inwardly in a longitudinally convergent chute, into generally superimposed condition. Pusher means urges the sheet-like stock material laterally toward a confronting surface of the chute. Then the inwardly rolled webs of stock are passed into a crumpler section where mechanism such as meshed gears attach together the confronting portions of the rolled edges of the stock material generally centrally, in a direction lengthwise thereof, to retain the dunnage product in highly compressible, lightweight pad-like form. A transfer vehicle is adapted to coact with the dunnage producing mechanism for storing a preselected amount of the pad-like dunnage product on the vehicle, whereupon the vehicle can be moved to a location distant from the dunnage producing mechanism for use at the distant location. A novel method of producing and transferring the pad-like dunnage is disclosed.

Description

`- ~6)7Z795 CUSHIONING DIJ~NAGE MECEIA~ISM, TRAl!ISFER CART TH15REFOR, ~D 11ETHOD
SPECIFICATIO~
This invention relates in general ko mechanism for producing packing material or cushioning dunnage as it is known in the art~ and more particularly to a dunnage producing me-chanism for the production of a continuou~, highly resilient, pad-like dunnage product from sheet-like stock material dis-posed in a composite multi-ply stock roll. A transfer vehicle or cart is usable in conjunction with the dunnage producing mechanism for transferring preselected amounts of the pad-like dunnage to locations distant rom ~he dunnage producing ma-chine. The invention also relates to a novel method of pro-ducing and transferring the pad-like cushioning dunnage product.
BACKGROUND OF T~E I~VE~TIO~
In United States patent ~o. 3,799,039 isQued March 26, 1974 to George R. Johnson and entitled "Cushioning Dunnaga Mechanism and Method" there is disclosed a cushioning dunnage producing mechanism of the general type of the present inven-tion, for producing a generally similar pad-like cushioning dunnage product. While such prior art mechanis~ represented a considerable improvement over previous prior art arrangements for producing cushioning dunnage, there were still problems involved in the use of the machine illustrated in such patent.
One of the problems was the tendency of the sheet-like stock material to tear during the dunnage producing operation and during its movement from a composite roll of the stock matarial into the crumpler section of the machine. Tearing of the stock material generally necessitated shutting down of the machine 1~'7'~'7~

and reinserting non-torn portion~ of the web~ from the stock roll into the crumpler mechanism, so that a high quality dunnaga pad could be produced in the mechanism. Moreover, with the arrange-ment disclosed in the patent 3,799,039, khe dunnage material pro-ducted was generally used at the location o or in the immediate vicinity of the dunnage producing machine, and the trans~er of the dunnage pad material to another location was not too convenient.
SUMMARY OF THl: I~VENTION
~he pre~ent invention provides a novel dunnag~ produc-ing mechanism for producing from sheet-like 3tock material, such as paper, a pad-like cu3hioning dunnage product, and wherein the machine is an improved arrangement of the dunnage producing ma-chine of the aforementioned U.S. patent 3,799,039. Moreover, the invention provides a dunnage producing mechanism of the above de-scribed type which include~ a transfer vehicle for use in conjunc-tion with the dunnage producing machine, for expeditiously provid-ing for transfer of a preselected amount of the pad-like dunnage material fro~ the location of the machine to a location diq~ant from the dunnage producing machine, and in a manner wherein the dun-nage pad material may be expeditiously transferred from the pro-ducing machine to the transfer vehicle.
Broadly, the present invention is directed to a cushion-ing mechani~m for producing generally low density pad-like cush-ioning dunnage from flexi~le sheet-like stock material comprising, a support, means on the support for rotatably mounting a multi-ply roll of sheet-like stock mate~ al, crumpler ~eans on the support adapted to receive the sheet 1ike ~tock material thereinO the erump~
ler means having i3 stock material entry opening and a tock matex-ial exit opening spaced from the entry opening, means on the sup-port for ~eparating the sheets of stock material as the latter move ; ~ -2-~7Z795 from the roll toward the crumpler means, chute means for causing inward rolling o~ the lateral edge~ o~ the sheet-like material into ~enerally rolled form prior~to entry o the sheet-like stock material into the crumpler mean~, the chute mean~ including an en~
trance mouth disposed in confronting relation to the separating means, the chute means extending lengthwise between the crumpler means and the separating means and funneling rolled edge stock material toward the crumpler mean~, mean~ for connecting confront-ing rolled edges of the stock material together for producing a dunnage product of pad-like configuration, the connecting mean~
including maans for pulling the sheet-like ~tock material from the roll through the separating means and into the crumpler means, and the mounting means baing 90 disposed that the peripheral ex-tremity of the ~tock roll does not extend substantially beyond a longitudinal plane passing through a certain inner defining sur-face of the chute means at the entrance mouth, and th~ material from the stock roll is withdrawn therefrom in the general length-wise direction of extension of the chute means, and in combination with a mobile transfer cart adapted to be spaced from the mechan-20 ism and having means on the cart for winding dunnage produced bythe mechanicm onto the cart for subsequent transfer to an area remote from the dunnage mechanism, the cart including means for anti~friction movement of the cart over a floor surface to the re-mote area.
Further obJects and advantages of the invention will be apparent from the following description taken in conjunction 1~7;~'7~S

with the accompanying drawings wherein:
BRIEF o~S RIPIIo~ OF IN] D ~WINGS
FIGURE 1 is a somewhat diagrammatic side elevational view of a mechanism embodying the present invention, and in-cluding a transfer cart or vehicle.
FIGURE 2 is a top plan vie~ of the mechanism of FIGURE
l;
FIGURE 3 is a generally perspective view of the dunnage producing machine of ~IGURES 1 and ~ taken from the rear thereof;
FIGURE 3A is a fxa~mentary view of a modified stock roll embodying adhesive means on at least certain of the webs or sheets of stock material for securing the confronting por-tions of the rolled edges of the stock material together ~or maintaining the pad-like configuration oE the dunnage product.
FI&URE 3B is a fragmentary view similar to FIGURE 3A
but illustrating a modifi~d arrangement.
FIGURE 4 is a perspective view of the dunnage pro-ducin~ machine of FIGURES 1 and 2 taken generally ~rom the front thereof;
FIGURE 5 is a fragmen ary detailed view of the crum~-ler portion of the dunnage producing mechanism, together with power operated gears or pulling the stock material through the dunnage producing machine and for joining or stitching the superimposed inwardly rolled edges of the stock material into an integral pad-like product, FIGURE 6 is a view taken from the opposite side of the mechanism illustrated in FIGURE 5;
FIGURES 7 and 8 are respectively front and side ele-'7'2'i~S

vational views of cuttiny mechanism ut:ilizable in the dunnage producing machine, for cutting the dunnage product produced on the machine;
FIGURES 9 and 10 are respectively front ~levational and top plan views o~ the chute of the machine;
FIGU~ES 11 and 1~ are parspective views o the trans-fer vehicle or cart adapted for use in conjunction with the dunnage producing machine, for receiviny the pad-like dunnage product from the continuous production on the machine, storing or suppoxting on same on the transfer vehicle, and providing for subsequent transfer of the preselected amount of the dunnage pad material to an area or location distant from the area of production of the dunnage producing machine.
FIGURE 13 is an enlarged top plan detailed viaw of pusher mechanism for mounting in the chute of the dunnage pro~
ducing mechanism of FIGURES 1 and 2;
FIGURE 14 is an elevational view of the FIGURE 13 structure;
FIGURE 15 is a diagra~matic, schematic illustration of a control circuit for the dunnage producing machine;
FIGURE 16 is a top plan view of a modified arrange-ment of dunnage producing machine;
FI(,URE 17 is a side elevational view of the FIGU~E
16 machine;
FIGURE 18 is an end elevational view taken generally along the plane of line 18-18 of FIGU~æ 17;
FIGU~E 15 is a fragmantary view of the pad~like dun-nage product produced on a dunnage machine utilizing a stock i ... .. . .

~o~z~s roll of FIGURE 3A embodying adhesive means for attaching toget-her confronting portions of the exterior sheet of the stock sheet matexial.
DESCRIPTIO~ OF THE PREFE~ED EMBODIMENTS
Referring now again to the drawings, there is illus-trated a dunnage producing machine 10 which utilizes a single multi-ply stock roll 12 of sheet-like material such as, ~or instance, Kraft paper. In the embodiment illustxated, the stock roll 12 comprises a hollow cone 14 of generally cylindrical configuration on which are rolled three superimposed webs or runs 16, 17 and 18 of paper stock material. The roll of stock material is adapted to be mounted on a supporting rod 19 ex-tending through ~ore 14, for rotation of roll 12 relative to the support structure 20, as the paper stock is drawn into ~he dunnage machine 10 Open top, standing U-shaped guides 22 are provided, in the embodiment illustrated, for generally loosely receiving the ends of the rod 19 and retain the rod on the support struc-ture 20 while provi~ing for rapid replacement of the stock roll when necessary. In the embodiment illustrated, the three super-imposed webs 16, 17 and 18 of paper stock are of generally equal width. As an example, the elongated roll of stock material may be of a dimension of approximately 9 ~nches in diameter by approximately 28 to 30 inches in width~ However, as will be hereinafter dis~ussed, the diameter of the roll is not particu-larly important so far as operation of the machine is concerned.
What is important is the location of the per~phery of the roll as relatad to the entranceway to the c~ute of ~he mechanism, in order to aid in preventing tearing oE the sheets of stock as they come off the roll, and as will be hereina~ter discussed.
One end o~ the rod 1~ extendins~ through the stock roll, is adapted to have an opening therethrough receiving a pin pro-jecting laterally from the rod, for preventing rotation of the rod upon rotation of t~e roll about rod 19. In other words, the roll of stock frictionally rotates ralative to the rod 19 during pulling of the stock material into the dunnage producing mechanism in the embodiment illu~trated.
Machine 10 comprises, in the embodiment illustrated, a support frame 24, including leg portions 24a which preferably include means 25 associated therewith for leveling the support frame with respect to the supporting surface S.
Frame 24 supports a longitudinally converging chute 26 (FIGURES 1, 9 and 10) w~ich chute forms a guide and support for the webs of stock material 16, 17 and 18 as they are drawn off tha stock roll 12 and are passed to a longituainally elonga-ted crumpler section 28 of the dunnage producing machine. In ~he e~bodiment illustrated, the chute 26 and the crumpler sec-tion 28 may be provided as an integral unit which can be con-veniently formed of, for instance, fiberglass or plastic or Qome other such suitable material.
As can be best seen in FIGURES 1, 2 and 9, the chute section 26 comprises a widened mouth or entranceway 30, with the upper, lower and side wall interior surfaces 3~, 34, 34a (FIGURE 2) oE ~he chute converging rearwardly with respect to one another and wi~h xespect to the entranceway. Entranceway 30 is of generally oval configuration (FIGURE 9), with the major axis X-X of the oval shape disposed in a generally hori-zontal plane which passes through the horizontal center plane of the crumpler section 28. The minor axis Y-Y oE the oval shaped entranceway i8 disposed in a vertical plane passing through the longitudinal center axis of the crumpler section 28. The top wall of the chute may be recessed as at 36 (FIGURES

2, 9 and 103 for providing accessibility to a pusher mechanism 40 (FIGURES 1, 14 and 15) which extends downwardly in dependiny relation from the top of the support frame to be closely spaced to the bottom wall surface 34 of the chute and as can be best seen in FIGURE 1.
Pusher mechanism 40 in the embodiment illustrated comprises a tubular body portion of generally triangular shape in plan (FIGURE 13) and is supported in the chute 26 in rela-tively closely spaced relation to the bottom interior surface 34 thereof by front and rear threaded rods 44, 44a extending through recess 36 in the chute. Threaded sockets 46 are pro-vided on the body portion of the pusher mechanism, which receive one end of the associated rod 44 or 44a.
The other end of the rod extends through a support bar 48 (FIGURE 2) and is secured to the bar 48 a~ by means of associated nuts 50. A plurality of longitudinally spaced open-ings may be provided in the bar 48 for selective adjusting of the position of the pusher with respect to ~he chute 46. It will also be seen that the nuts ~0 provide for adjustment for the relati~e closeness of the body portion of the pusher with respect to the confronting surface 34 of the chute.
As ~an be seen in FI~URE 2, the body portion of the ~ f~'79~
pusher occupies a ~ubstantial portion of the crosswise dimen-sion of th~ bottom wall of the chute, and causes the sheet-like stock material as it passes from the stock roll 12 to ~he crump-ler section 28 to be generally conformed to the chute, thereby causing ef~ective inward rolling of the lateral edges of the webs of stock material.
The body portion of the pusher means being formed of rod or tube material ha~ rounded edges, and as it recei~e~ the -;^
stock material there beneath, urges it downwardly toward the bottom wall of the chute and aids in preventing tearing of the webs o stock material coming off st~ck roll 12u A wheeled counting mechanism 52 may be provided, sup-ported as by means of the aforementioned bar 4B, fox detarmining ~he amount or linear ~ootage of dunnage material produced by the dunnage machine. A top co~er 53, which may be hinged as at 53a provides convenient access to the interior of the machine and to the pusher mechanism 40 and counting mechanism 52.
Mounted on the frame 24 downstream from the rotational mounting 19 o~ the s ock roll 12 is a separating means 54 (FIG-URE 1). In the embodiment illustrated separating means 54 com-prises a plurality of vertically spaced bar-like elements 54a, 54b, and 54c, through which is adapted to pass the webs from the stock roll 12. As can be seen from FIGURE 1, the upper web 16 is adapted to pass beneath separator rod 54a, while the middle web 17 passes beneath the separator rod 54b, and the lower web 18 passes beneath the lower ~eparator rod 54c.
The separator mechanism maintains the webs in separated condition prior to their being urged back into generally juxta-.

1~7Z~5 posed condition at the pusher mechanism 40, the latter being downstream from the preferably cylindrical ~eparator rods. The lowermost rod 54c is disposed just slightly above the bottom periphery of the entranceway 30 to chute 26, and with sufficient clearance so as to permit ready entry of fhe stock web 18 there-beneath.
In accoxdance with the invention, the axis of rotation of the stock roll is so positioned that the periphery of the stock roll 12 as initially loaded on the machine is maintained substantially no lower than and preferably higher than a hori-zontal plane passing through the aforementioned entranceway bot-tom periphery 55 to the chute 26. Such positioning of the stock roll periphery aids in preventing tearing of the webs of stock material as they are pulled off the stock roll and are directed toward the crumpler section 28.
Crumpler section 28 preferably has slots 56 (FIGURE 10) .
in its upper and lower walls into which extend connecting or stitching maans 58 (FIGURES 5 and 63 for connecting confronting portions of the generally loosely crumpled stock material toget-her as the latter is drawn through the ~rumpler section by the connecting means. In this connection, the cDnnecting means comprises in the FIGURES 5 and 6 embodiment, generally loosely meshed equal size spur gears 58a, 58b which are rotatably mounted as by means of a respective shaft 60, 60a, for ro~ation relative to the crumpler section 28. 5haft 60 o* upper gear 58a is pre-ferably arranged so that the ends of the shaft are mou~ted in a slotted bracket frame 62 (FIGURE 5) with the ends of the shaft being spring loaded as at 64, for urging the shaft downwardly :~

~0'7~ 9~

toward the underlying geax 58b. It will be seen, thereore, that the top gear 58a generally "floats" in its suppoxting slot-ted bracket structure 62, with the gear 58a being movable ver-tically relative to the underlying gear 58b, to thus provide for tension varying of the spacing between the gears as di~fer-ent amounts or thicknesses of material pass therebetween. Such an arrangement aids in preventing tearing of the stock material due to too hard mesh~ng between the connecting gears.
q~e lower shaft 60a may be rotatably mountad in s~a-tionary beaxing structure 66 (FIGUR$ 6) and includes a sprocket 67 secured to one end thereo~, which in turn i~ connected by endless chain ox belt 68 to geared speed reducer 69, the latter being driven by an electric motor 70 mounted on the machine frame 24. It will be seen that actuation of the motor 70 will cause rotation of the meshed gears 58a, 58b thus not only coining the stock material by rotation of the gears but also pulling the crumpled stock material through the mechanism.
The lateral edges of the webs 16~ 17 and 18 of the stock roll after they pass the transversely extending separating rods 54a, 54b and 54c commence to be turned inwardly by the curved walls of the chute 26. Thus when the rolled edges of the webs reach the narrowed entrance mouth 72 of ~he crumpler ~ection 28, they have been rolled substantially inwardly into generally abutting con~ronting rela~ion with one another and wherein the web stock material is crumpled radially inwardly by the crumpler section and then is coined or joined along the central porti.on thereof by the afoxementioned meshing gears 58a, 58b.

~L~7Z'795 ~ he webs 16, 17 and 18 are pulled from the peripheryof ~he stock roll 12 in a zone defined by the aforementioned horizontal plane passing through chute entrance periphery 55 and a horizontal plane passing generally through or at the core tube 14 of the stock roll. It will be seen that at least ini-tially when the stock roll is the heaviest, the periphery o~
the roll will in general be disposed in confronting relation to a zone defined by longitudinal planes passing through the uppermost separating rod 54a and the aforementioned chute en-trance periphery 55. A~ter considerable depletion of the ~tocX
roll and therefore considerable lightening therevf the periphery thereof in ~he embodiment illustrated, will move above a hori-zontal plane passing through the separating rod 54a.
The afore~entioned pushing mechanism 40 urges the webs o~ stock material into engagement with one another during the inward rolling of the lateral edges of the webs, and aids in maintaining alignment of the stock ~aterial in its movement toward the crumpler section 28.
After passing from the exit opening 74 of th~ crumpler section 28, the continuously formed pad P (FIGURE 4) of stock mat~rial may be severed by the cutter mechanism 76 mounted on the rear end of the machine at the exit opening 74 therein.
Cutter mechanism 76, in the embodiment illustrated, comprises a cutter framework 78 (FIGURE 7) in which is m~vably mounted a cutter blade 78a which has a sharpened, preferably replaceable edge 79 adapted for cuttin~ coaction with a sta-tionary cutter edge 78b on the upper cross piece 80 of the cut-ter frame. Cutter frame 78 includes side leg portions 82, 84, ~7Z795 each of which is of hollow construction (FIGURE 8) and embodying a guideway or track 82a or 84a (FIGURE 8) adapted to receive guide means 86 (in ~he embodiment illustrated rotatable wheels) on the cutter blade 78a for guiding the movement of the cutter blade 78a relative to the cutter frame 78. The wheels 86 are rotatably mounted on and with respect to the blade 78a and are received in rolling relation in the respective guide track 82a or 84a in the respective leg of the cutter frame 76.
Cutter blade 78a is pivotally coupled at 88 to a re-ciprocal double acting fluid powered motor unit 87 (FIGURE 7) with the pivotal connection of the motor unit to the blade being offset in a direction toward the longer leg portion 84 of the cutter frame 78, and as can be best seen in FIGURE 7. The other end of the motor unit 89 is pivoted as at ~0 to a bracket 92 mounted on the support frame for the dunnage machine. ~rackets 94 on the cutter frame locate and aid in supporting table sur-face 96, on which the pad-like dunnage may be supported a~ it is emitted by the mechanism.
Motor unit 89 is adapted to he controlled in its re-ciprocal actuation by means of a pair of control buttons 98, 99 mounted on the table surface 96 extending rearwardly from the frame of the dunnage machine. By having two control buttons in order to cause actuation of the cutter unit 76, both hands of the operator are maintained exteriorly of the cutter unit and protected from injury during actuation of the cutter unit.
In accordance with the invention, transfer ve~icle 102 is provided, for receiving a predetermined amount of dun-nage pad from the dunnage machine, winding it into a roll R

:107Z795 (FIGURE 1) and supporking it on the vehicle for sub~equent trans-fer to an area distant from the dunnage machine 10.
The transfer vehicle 102 comprises a preferably light-weight frame 106 which has wheels 108 rotatably mounted thereon, for making the frame readily movable, and which may include a rotatable shaft 110 having some means ~hereon for initially se-curing the end of a strip of dunnage pad material thereto, dur-ing rotation of the shaft 110. Such means in the embodiment illustrated comprises a U-shaped bracket 112 attached to and projecting laterally from the shaft and which is adapted to re-ceive the free end of the dunnage pad being produced by the machine and hold it during rotation of the shaft 110, as by means of removable handle 114. Khen the roll of dunnage material col-lected is of desired size, then either the cutter mechanism 76 on the dunnage machine, or the cutter 116 on the transfer cart, can be actuated to cut off the pad from the continuous length ::
being produced by the dunnage machine, and ~he roll of dunnage material on the transfer cart is then available for expeditious movement by means of the transfer cart, to a selected area which may be distant from the dunnage machine.
When the cart or transfer vehicle 102 is moved to the desired location the manually operable cutter ~lade 116 can be utilized to cut the dunnage roll R into the desired l~ngths at the area to which ~he cart has been transported to. The trans-fer cart preferably has diagonally extending hand gripping por-tions 118 and cross portion 118a for gripping by a workman, and for tipping the cart rearwardly so that it is supported on the wheels 108, for easy movement. The other end of ~he cart with ... .. .

the cutter mechanism 116 and associated support board 120 there-on is of such weight that upon release of the handle portions 118, said other end of the cart tips downwardly by gravity and is supported by the end 112 (FIGURE 1) o the frame portion 106 of the cart.
It will be seen therefore, that with the t;ransfer cart, the production of the dunnage pad P from the dunnage machine can be used much more expeditiously, by providing an arrangement for rapidly receiving a selected amount of the dun-nage pad from the producing machine and facilitating movement of such selected amount to an area which is remote from the machine, thus enabling the dunnage pad product to be utilized in various areas of an establishment without the necessity of having a dunnage producing machine located at each area wherein use of dunnage is desired.
Referxing now to FIGURES 16, 17 and 18 there is illus-trated another embodiment of the dunnage machine which is a more compact nature in a horizontal or width direction as compared to the first described embodiment~ In this arrange-ment, the stock roll 12' is mounted for rotation about a ver~
tical ~xis, with the lower end of the shaft 19' whic~ extends through the hollow core tube 14' of the stock roll, being re-ceived in a complementary opening in turntable 230, which is rotatably mo~mted on bracket structure 20' for rotation about a generally vertical axis, the latter being coincident with the axis of t~e rod 19'~
The upper end of the rod 19' is received in supported and preerab]ly clamped relation by m~ans of ~uitable readily 7~79~i releaseable clamping means 232, mounted on upper support 20'', so ~hat the stoc~ roll 12' can be rapidly mounted on the turn-table and clamped by clamping mechanism 232, for rotary move-ment, The webs 18, 17 and 16 coming from the stock roll 12', pass through the divider means 30' in a generally similar manner as in ~he first described embodliment, except that ~he webs are generally vertically oriented as compared to being generally horizontally oriented as in the irst described embodiment.
Divider means 30' comprises vertically oriented rods 54a', 54b', 54c' coarting to cause separation of the webs 16, 17 and 18 from the stock roll, in a generally similar manner as in the first described embodiment. The chute means 26 in this embodiment may be of the same structural arrangement as in the fir~t described embodiment, except that it is tipped on its side so that the major axis X-X of the oval shaped mou~h or entranceway 30l to the chute means 26' is vertically dis-posed as compared to the hori~ontal ori~ntation of the first described embodiment.
It will be seen that ~he separating rod 54r ~ coacts with the adjacent surface 34' of the chute means in the same general way that ~he rod 54c coacts with ~ha corresponding surface 34 o the chute of the first described embodiment, and also that ~he periphery of the stock roll 12' i9 oriented with respect to a longitudinal plane passing thLough the sur-face 34' of the chute means of ~his embodiment in a similar relationship as in the first described embodiment.
A pusher mechanism 40~ may coact with surface 34' in 1 c37~95 a similar manner as in the first described embodiment, and the webbed stock material from the ~tock roll passes beneath the pusher and into the crumpler section 28', where it is radially inwardly compressed in a similar manner as in the first des-cribed embodiment, to produce a pad-like dunnage product at the emitting end of the mechanism.
A cutter mechanism 76' may be mounted at the emitting end or mouth 74' of the dunnage mechanism, for cutting the dun-nage material into selected lengths. In mo~t other re~pect~, the FIGURES 16, 17 and 18 embodiment is generally similar to the first describad embodiment, with similar reference numbers being utilized to designate similar parts with the addition of the suffix (') prime thereto.
It will be seen that one of the advantages of the FIGUR~S 16, 17 and 18 embodiment is that it utilizes much less floor space for a dunnage machine, and w~ile the dunnage pro-duct comes out of the machine tipped generally on its side as compared to that in the first described embodiment, it (the product, since it is very flexible) can be turned for coaction with a transfer cart (not shown) in a similar manner as that utilized in the first described embodiment.
FIGURE 19 disclo~es another embodiment of dunnage pro-duct wherein the outer web 18' of the stock material has been provided with a strip 234 of adhesive, such as for instance pressure sensitive adhesive, along at least one lateral edge thereof. Thus when the webs are radially crumpled and placed into generally confronting relationship with one another, the strip 234 of adhesive is used to connect the confronting por--~7-:, . . .. . , . . ., ,:

~LID7'~'~9~

tions of the inwaxdly turned or inwardly rolled lateral edges of the ~tock webs together, to maintain the dunnage product P' in pad-like form. In this connection rather than having meshed gears 58a 58b coacting with the stock webs for coining or coup-ling them together, plain rollers or wheels could be ut.ilized for compressing the confronting portions of the web stock materi-al together so that the pressure sensitive adhesive strip 234 will be positively forced into sealing or securing contact with the confronting portion of the web, to hold the dunnage product in the pad-like form illustrated.
It will be seen that if wheel connecting means are used in lieu of the geared means illustrated in the first des-cribed embodiment, that the central section 236 of the dunnage product P' will be of a lesser thickness dimension as compared to the lateral pillow like portions of ~he product, and in a similar manner as the product produced by ~he geared connecting means, except that the product is held together not by coining of the webs, but instead by the strip of adhesive material. It will be understood, of course, that the geared connecting means could be utilized in conjunction with stock material utili~ing adhesive connecting means rather ~han plain rollers, but with the adhesive strip, it is not necessary to also coin or mechan-ically stitch the stock material together, to hold it in its pad-like form.
Referring now to FIGURE 15, there is shown schematic-ally, a control system for controlling operation of the dunnage mechanism of either the FIGU~ES 1 and 2 embodiment or the FIG-URES 16, 17 and 18 e~hodiment. ~he æystem is adapted for plugging - . ,. . ; . ,, .,: . : :, : . ,: :

~Z7~35 into a conventional 115 volt AC source 237 o:f power.
A "momentary run" swit:ch 238 (FIGURES 1, 2 and 13) is provided for momentarily actuati.ng the drive motor 70 of the mechanism so long as the switch is held in compressed condi~ion, for producing a selected amount of cushioning dunnage. Switch 238 is spring loaded and when actuated, the normally open con-tact thereof closes and the norrlally closed contact thereof opens, whereby the electric motor 70 i5 enexgized ~rom the source of power 237. When the finger of the operator is removed from the switch button, the spring of the switch causes the normally open contact to reopen and the normally closed contact to close, thereby automatically deactuating the motor 70.
There is also provided a "maintained run" switch 240.
The maintained run switch 240 is a maintained on-off type switch, so that when the manual actuatlng button 240a for thP switch is pushed in one direction~ the normally open contact of the switch closes and the normally closed contact opens and such condition is maintained when the finger of the operator is removed from the switch button. When the button 240a is repushed, the nor-mally open contact opens, and the normally closed contact is once again clo~ed.
Also located on table surface 96 on opposite sides of the exit mouth 74 of the dunnage machine is a auxiliary leftt cutter actuating switch 244, and a a~xiliary right hand cutter actuating switch 246, which are arxanged in series with a mas-ter cutter actuating switch 248. Switch 248 can be disposed generally centrally of the dunnage mechanism above the exit mouth thereof, and as can be seen in FIGV~E~ 1 and 2.

1al7Z~7~5 Either the left hand auxiliary switch 244 or the right hand auxiliary switch 246 must b,e actuated in conjunction with the master switch 248 in order that energization o~ the fluid actuated motor unit 89 actuating the cutter mechanism 76, can J
occurO It will be seen upon actuati~n of master qwitch 248, the normally open conta~t is closed and upon actuation o~ one or the other of the auxiliary cutter switches 244 or 246 the solenoid 250 controlling the flow of actuating fluid, such as for instance pressurized air~ to the motor unit 89 is energized, to cause application of pressurized fluid to entry port 252 (FIGURE 7) thereby causing outward projection of the piston rod of the motor unit, to cause the cutter blade 78a to move in its guided trackways 82a, 84a into cutting coaction with the upper stationary cutter blade 78b, thereby cutting off the dunnage pad at the selected length. Upon release of the actuating button of the auxiliary cutter switch or the button of the master switch, the normally closed contact of the auxiliary switch once again automatically closes, and the normally closed contact of the master switch once again automatically close~, thereby de-ener-gizing the solenoid and the associated air valve automatically applies pressurized air to port 252a of motor unit 89, to move the cutter blade 78a downwardly along its guide paths whereby the cutter blade 78~ is disposed in retracted condition.
It will be seen therefore that the both hands of the operator are necessary or occupied in order to actuate the cutter ~-mechanism 76, and therefore such arrangement provides a safety system to insure that the hands of the machine operator can not be located in a position where they could be injured by the cutter .,.~

`: ;

7~7~

mechanism, upon actuation ~hereof.
A cover interlock switch 254 (FIGURE 13) is also pre-ferably provided in the control system to disable the electric power to the machine from ~he source, in the event that cover 53 (or 53'~ is not disposed in completely closed condition.
From the foregoing description and accompanying drawings it will be seen that the invention provides a novel dunnage machine for producing r~latively low density pad-like cushion-ing dunnage, and wherein the dunnaye can be rapidly a~d effec-tively produced by the machine without tearing of the stock material, and wherein the continuously produceable dunnage pad from the machine can be expeditiously stored on a transfer cart for subse~uent trans~er to areas remote from the dunnage machine.
The invention also provides a novel method for producing and handling the dunnage material, greatly facilitating the produc-tion o dunnage from a single dunnage machine, as well as pro-viding a novel stock roll for at least one embodiment of the dunnage machine.
The terms and expressions which have been used are used as terms of description, and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described, or portions ~lereofO but it is recognized that various modifica-tions are possible wi~hin the scope of the invention claimed.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. In a cushioning mechanism for producing generally low density pad-like cushioning dunnage from flexible sheet-like stock material comprising, a support, means on said support for rotatably mounting a multi-ply roll of sheet-like stock material, crumpler means on said support adapted to receive the sheet-like stock material therein, said crumpler means having a stock mater-ial entry opening, and a stock material exit opening spaced from said entry opening, means on said support for separating the sheets of stock material as the latter move from said roll toward said crumpler means, chute means for causing inward rolling of the lat-eral edges of the sheet-like material into generally rolled form prior to entry of the sheet-like stock material into said crumpler means, said chute means including an entrance mouth disposed in confronting relation to said separating means, said chute means extending lengthwise between said crumpler means and said separ-ating means and funneling rolled edge stock material toward said crumpler means, means for connecting confronting rolled edges of the stock material together for producing a dunnage product of pad-like configuration, said connecting means including means for pulling the sheet-like stock material from said roll through said separating means and into said crumpler means, and said mounting means being so disposed that the peripheral extremity of said stock roll does not extend substantially beyond a longitudinal plane pas-sing through a certain inner defining surface of said chute means at said entrance mouth, and the material from said stock roll is withdrawn therefrom in the general lengthwise direction of exten-sion of said chute means, and in combination with a mobile transfer cart adapted to be spaced from said mechanism and having means on said cart for winding dunnage produced by said mechanism onto said cart for subsequent transfer to an area remote from said dunnage mechanism, said cart including means for anti-friction movement of said cart over a floor surface to said remote area.

2. The combination in accordance with Claim 1 wherein said cart includes a rotatable spindle for receiving the end of an associated strip of dunnage from said dunnage mechanism, means on said spindle for holding the dunnage material coupled thereto, and means for rotating said spindle.

3. The combination in accordance with Claim 1 includ-ing cutter means disposed downstream of said crumpler means for cutting the dunnage product into selective lengths.

4. The combination in accordance with Claim 1 wherein said chute means extends continuously from said separating means to said crumpler means, the central axis of said entrance mouth of said chute means being disposed substantially in a horizontal plane passing through the longitudinal axis of said crumpler means.

5. The combination in accordance with Claim 1 wherein said chute means and said crumpler means are integrally molded as a unit.

6. The combination in accordance with Claim 1 includ-ing pusher means coacting with said chute means, and wherein said pusher means comprises a generally triangular shaped member extend-ing generally longitudinally and transverse to said chute means and being spaced closely adjacent to said certain surface of said chute means, said pusher means being adapted to receive the mov-able sheets of stock material between said pusher means and said surface.

7. The combination in accordance with Claim 1 wherein said chute means includes upper and lower walls and side walls with said walls converging in a direction toward said crumpler means and merging therewith at said entry opening of said crumpler means, and wherein said upper wall of said chute means is slotted along a vertical plane passing through the longitudinal axis of said chute means, and pusher means extending through said slotted upper wall into relatively close proximity with said lower wall thereof, said pusher means occupying a substantial portion of the transverse dimension of said chute means and adapted to cause the sheet-like stock material to generally conform to said chute means as the stock material passes from the stock roll to said crumpler means.

8. The combination in accordance with Claim 1 wherein said separating means comprises a plurality of generally vertical-ly spaced bars extending transverse of said support and about which a respective sheet of the stock material moves in its travel tow-ard said crumpler means, the axis of rotation of said roll mount-ing means being disposed in a horizontal plane disposed above a horizontal plane passing through the upper most of said sheet sep-arating bars, and wherein the material of the stock roll is adapted to be withdrawn from the underside of the roll into said separating means.

9. The combination in accordance with Claim 1 including cutter means disposed downstream of said crumpler means for cutting dunnage product into lengths, and wherein said cutter means com-prises a frame having guideway means therein, and a movable cutter blade having means thereon received in said guideway means for guid-ing the movement of said blade relative to said frame, and an upper coacting cutter blade adapted for cutting coaction with the first mentioned movable blade for cutting the dunnage material into pre-determined lengths upon predetermined actuation of associated re-ciprocable power means.

10. The combination in accordance with Claim 1 wherein said mounting means is arranged for vertical mounting of the stock roll for providing a relatively narrow width mechanism, and where-in said mounting means comprises a turntable.

11. The combination in accordance with Claim 4 wherein said entrance mouth of said chute means is of generally oval con-figuration in elevation with the major axis thereof extending in a generally horizontal plane and the minor axis thereof extending in a generally vertical plane, the latter passing through said lon-gitudinal axis of said crumpler means, said separating means com-prising a plurality of generally vertically spaced bars extending transverse of said support and about which a respective sheet of the stock material moves toward said crumpler means, the axis of rotation of said roll being disposed in a horizontal plane disposed above a horizontal plane passing through the uppermost of said sheet separating bars.

12. The combination in accordance with Claim 5 wherein said integral chute means and crumpler means are formed of fiber-glass resin.

13. The combination in accordance with Claim 7 wherein said side walls of said chute means are of arcuate interiorly con-cave configuration in cross section and merge smoothly with said upper and lower walls.