CA1325797C - Dunnage converter for producing narrow width cushioning pad product, conversion kit therefor, and method - Google Patents
Dunnage converter for producing narrow width cushioning pad product, conversion kit therefor, and methodInfo
- Publication number
- CA1325797C CA1325797C CA000584763A CA584763A CA1325797C CA 1325797 C CA1325797 C CA 1325797C CA 000584763 A CA000584763 A CA 000584763A CA 584763 A CA584763 A CA 584763A CA 1325797 C CA1325797 C CA 1325797C
- Authority
- CA
- Canada
- Prior art keywords
- pad
- former
- article
- cushioning
- product
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D5/00—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
- B31D5/0039—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
- B31D5/0043—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material
- B31D5/0047—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material involving toothed wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
- B31D2205/0017—Providing stock material in a particular form
- B31D2205/0023—Providing stock material in a particular form as web from a roll
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
- B31D2205/0047—Feeding, guiding or shaping the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
- B31D2205/007—Delivering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0076—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads involving particular machinery details
- B31D2205/0082—General layout of the machinery or relative arrangement of its subunits
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S493/00—Manufacturing container or tube from paper; or other manufacturing from a sheet or web
- Y10S493/967—Dunnage, wadding, stuffing, or filling excelsior
Abstract
DUNNAGE CONVERTER FOR PRODUCING NARROW WIDTH CUSHIONING PAD PRODUCT, CONVERSION KIT THEREFOR, AND METHOD A converter mechanism and method for producing a relatively narrow width and small size cushioning dunnage product of pad-like form, from sheet-like stock material. A conversion kit comprising a funnel-like chute member and a coacting elongated generally rectangular shaped (in top plan) bar former is provided for conversion of a known cushioning dunnage converter into one which can produce the relatively narrow and small size pad-like cushioning dunnage product of the invention. The bar former has its forwardmost end disposed generally adjacent the exit end of the funnellike chute member, with its rearward end extending rearwardly of the entrance to the funnel like chute member. The narrow width and small size dunnage product produced on the instant converter mechanism possesses a density of approximately one pound per cubic foot, and is between approximately 3-1/2 inches to approximately 4 inches in width and approximately 1 to 11/4 inches in thickness, and is especially useful for packaging and cushioning small parts, as well as for effectively cushioning edges of products, for instance furniture or the like, during shipment thereof.
Description
-2- ~325797 SPECIFICATION
Thi~ invent~o~ relates in general to dunnage converter mechanism ~or producing dunnage product of pad-like form from sheet-like stock material and more particularly relates to a dunna~e converter for producin~ from sheet-like stock material, such as papex, a continuous strip of resilient, relatively narrow and small size pad-like dunnage product, which can be expeditiously used for cushioning and packaging relatively small parts, as well as for use in protecting the edges of products during shiplnent thereof, such as for instance the edges of furnitur~e including the arms and leg~ thereof, and the like.
With this invention, known converter mech~nism for i.
pr~ducing relatively wide, pad-lik2 cushioning dunnage produc~ is able to be expeditiously converted in the ~ield into a converter mechanism of the present invention for produclng relatively narrow pad-like cushioning dunnage product, and by means of the utillza~ion of a novel conversion kit, which includes a .funnel-like chute member and an elongated, bar-like former ~nembert which is mounted in the exist~ng converter mechani~m, and which changes the size o~ the produced pad like cu~hioning dunnage product. Also the multi-ply stock roll utilized in this invention for providing the sheet-like ~tock makerial to form the cushioning dunnage product, is of a materially lesser width as compared to that used in the aforelnentioned kno~n cushioning dunnage converter mechanisms, and in this connection, positioning elements are provided coacting with the lesser width stock roll, for properly maintaining ths position of the lesser width stock roll on the revamped converter mechanism.
132~797 BACKGROUND OF THE INVENTION
Cu~hioning dunnage producing mechanism for producing a resilient pad-like cushioning dunnage product having lateral pillow like portions centrally connected as by 5 colning andtor a~hesive means, are ~nown in the art.
~pplicant's U.S. Patent No. 4,750,896, issued June 14, 1988 in the names o~ ~nthony J. Komaransky and Raymond Q. Armington and entitled Method and Mechanism ~or Producing Cushioning Dunnage Product~
10 discloses a cushionin~ dunnage converter mechanism of the general type as that to whicll the present invention is dlrected. Such prior art converter mechanism includes a funnel-like chute membex which coacts with a triangular shape tin plan) forming ~rame, for forming the 15 sheets of stock material for a multi-ply stock roll into rolled con~i~uratlon prior to their passing into and through coacting rotatable connecting gears, which "coin"
the rolled edge stock material, and produce a full or conventional size pad-like cushioning dunnage product of 20 about 8 to 10 inches in wldtll, having laterally arranged, resilient plllow llke por~ions, which are connected centrally o~ the pad like dunnage product, running lengthwise thereof.
There are other prior art patents disclosing dunnage 25 producing mechanism and methods ~or producing a t resilient cushioning dunnage product Qf the general pad-like type of abovementioned U.S. Patent No. 4,750,~96.
U.S. Patent ~,026,198 to Gary W. Ottavaino dated May 31, 1977 and entitled Cushioning Dunnage Mechanisml Transfer 30 Cart Therefor and Method, discloses a cusllioning dunnage producing converter mechanism which produces a ~ull size resllient pad like dunnage product comprising lateral, resilient, pillow-like portions connected along the central portion of the pad runnin~ lengthwise thereof, 35 together with methods and apparatus for produc~n~ the same.
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` -4~ 1325797 U.S. Patent 3,655,500 dated Aprll 11, 1972 to G. R.
Johnson and entitled ~ Resilient Cusllionin~ Dunnage Product for Use in Packaging and Packlng, and U.S~
Patent, 4,109,040, dated August 22, 197~ to Gary WO
Ottavaino and entitled Cushioning Dunnage Product Produced from Cushionillg Dunnage Mechanism, disclose full size resilient pad like dunnage producks comprising lateral, resilient, pillow-like por~ions connected along the central portion of the pad running lengthwise thereof.
Applicant's Canadian Patent No. 1,243/300, issued November 1, 1988 in the name of Gary W. Ottavaino, and entitled ~echanism and Method for Producing Cushioning Dunnage, discloses a relatively light weight cushionin~ dunnage product of the a~orementioned resilient pad like ~orm, but of the same yeneral width as those aforediscussed, together with a metllod and apparatus ~or producing the same.
The prior art converter mechallisms and the ~ull size pad like cushioning dunnage product produced ~hereby, are not the same as the narrow pad like cusllioning dunnage product produced on a converter mechanlsm u~ili2ing the conversion kit provided by the present inven~ion. The relatively narrow and small siæe pad like product of this invention ls m~re exped~tiously utilizable ~or packagin~ and wrapping small parts, and may also be more approprlately utilized in certain cushioning situations wherein the larger size of cushioning dunnage pad i5 not conveniently utilizable or adaptable, such as for instance in protecting and cushionlng sharp edges of articles, such as furniture and the lilce and/or for furniture leg and/or arm wrap, etc. during shipmen~ of the articles.
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_5_ 132~797 SUMM~RY OF THE INVENTION
The present invention provlde~ a no~el, pad like cushioning dunnage product, and method for the production thereof from sheet-like stock material, such as for lnstance paper, with the machine produced product comprising a relatively narrow, deformable pad lilce cushioning article between approximately 3-lJ2 inches to approximately 4 inches in width, and appxoximately 1 to 1-1/4 inches ln thickness, at its lateral edge portions, with the cushioning article compri~ing lateral rolled edge portlons of the sheet like stock ma~erial and which are ~oined generally centrally of tlle pad-like cusllioning article lenythwise thereo~, by transversely extending coined portions o~ the pad like article, and with the article possessing a density o~ approximately one pound per cubic foot.
The relatively narrow and small size pad like cushioning article i5 especially useful in the packaging of small parts, and is adapted for use in other cushioning situations whereln larger size pad-like cushioning product is not sultable or readlly adaptable. The converter mechanism or machine from whlch the narrow width cushioning article of the present invention is produced, may be generally similar to that disclosed in the aforementioned prior U~S. Paten~
4,750,896, except that such converter mechanism has been revamped by means of the conversion kit of this invention, for production of the narrower and smaller size o~ cushionin~ dunnage pad product, and as will be hereinafter discussed in detail.
The aforementioned conversion kit o~ this invent.ion comprises a ~unnel~like chute member and an elongated bar-like former mernber which i~ adapted to coact with the .. ~, ' ., .
-6- ~ ~25797 chute member in a generally known but revamped type of converter mechanism of the general type for instance of aforementioned U.S.Patent No. 4,7~0,&96together with utilization of a shorter width of multi-ply stock roll, to provide for the production of the narxower width and smaller size cushioning dunnage pad~like product of this invention.
Accordingly, an object of this invention is to provide a novel, relatively small size and narrow width cushioning dunnage product of pad-like form, for use as packing material and the like, especially useful in the packaging of small parts.
Another object of the invention is to provide a conversion kit which includes a funnel-like chute member and an elongated bar-like former member which is adapted for removable installation in a known type of converter mechanism, f~r enabling production of the aforementioned smaller size and narrow width cushioning dunnage product, utilizing the generally known type of converter mechanism, but as revamped by the conversion kit apparatus.
A still further object of the invention is to provide a conversion ket of the aforementioned type which includes a funnel-like chu-te member and a coacting elongated bar-like former member, which can be utilized in the field to convert a known dunnage producing converter mechanism, which conventionally produces full size cushioning dunnage product in pad-like form, into one that produces the relatively small size, narrow width cushioning dunnage product of the invention.
A still further object of the invention is to provide a novel method for the production of pad-like cushioning dunnage product of relatively small size and narrow width, which can be expeditiously utilized in the packaging of small parts, and for other cushioning uses _7_ 132~797 for which largQr or full siæe size cu~hioning dunnage pad product produced on a cushioning dunnage converter of known ~ype, is not readily adaptable for.
Other objects and advantages of the lnvention will ba S apparent froM the following description taken in con~unction wlth the accompanying drawings herein.
DESCRIPTION OF THE D~AWINGS
Figure 1 is a broken, partially sectioned, top plan view of a known dunnage converter mechanism which has been revamped by use of the conversion kit of the present invention, into a dunnage converter capable of producing the relatively naxrow small size pad like cushioning dunnage product of the invention.
Figure 2 is a partially sectioned, side elevational lS view of the mechanism of Figure 1.
Figure 3 is a partially broken, end elevational view of the mechanism of Figures 1 and 2, taken from the right hand or product exit end thereof.
Figure 4 is an end elevatlonal view of the mechani~m of Figures 1 and 2 taken from the le~t hand or s~ock material entry end thereof.
Figure 5 is a broken, fragmentary, end and perspective ill~stration of ~he relatively narrow small size pad like dunnage product produced on the revamped dunnage producin~ converter mechanism of Figs. 1-4.
Figure 6 is a top plan view o~ the funnel-like chute member of the conversion kit of ~he invention, which is adapted for installation into a known converter mechanisl~ for revamping it to produce ~he relatively narrow small size cushioning dunnage product of the invention.
Figure 7 is a side elevational view o~ the funnel member of Figure 6, taken from the right hand side thereof.
~325797 Figure 8 is a generally perspective illus~ration of the elongated bar like ormer member which is adapted for coaction with the funnel chute member o~ the conversion kit, when installed in a known converter mechanism1 the supporting rods for the ~ormer member are shown in bro}cen phantom linas; and Figure 9 is a fragmentary,side elevational view of the rearward end portion of the ~ormer member of Fig. 8 illustrating the use o~ slant wasllers with the associated support rod, for aiding in positioning o~ the ~ormer member in the converter mecl~anism.
DESCRIPTION OF PREF~RRED EMBODIMENT
Referring now again to the draw~nys, there is illustrated a dunnage producing machine 10 which is adapted to utilize a single, multi-ply stock roll 12 of sheet like stock material (such as ~or instance 3 sheets o~ 30 pound kraft paper) which are rolled into single roll form. In khe embodiment of stock roll illustrated in Figures 1 and 2, the plies of the stock roll are o~
equal width and comprise 3 plies disposed in roll form, for rotatable installation on tha dunnage producing converter mechanism 10.
The s~ock roll 12, in the machine embodiment illustrated, is approximately 15 inches ~n width, ~i.e., ln a direction transverse of machlne 10) as compared to a conventional stock roll of approximately 30 inch width, ~s conve~tionally used on dunnage converter mechanism of the ~eneral type illustrated and described for instance in aforementioned U.SO Patent No. 4,750,896.
Stock roll 12 in this embodlment, comprises a hollow core 14 (Fig. 4) of generally cylindrical tubular configuration on which the three superimposed webs or sheets of papar s~ock m~terial are wound. Stock roll 12 , ' .. ~
g is adapted to ~e mounted on a supportlng rod 16 extendlng relatively loosely through the core 14 o~ the roll, for rotation of the stock roll 12 and core 14 relative to the supporting bracket framework structure 18 o~ the converter Inachine 10. As khe stock material is drawn from the roll 12 into the dunnage converter machine 10, the roll 12 rotates in a clockwlse direction as viewed in Fig. 2.
In order to posltion the lesser width s~ock roll 12 on the supporting rod 16 generally centrally o~ the longitudinal axis of the dunnage converter machine~ a pair of sleeves 20 are slipped over the respective end o~
the stock roll supporting rod 16 and extend from the corresponding end o~ the stock roll to th~ respective arm lS ~2 o~ each supporting bracket 18 for the stock roll.
Thus, it will be seen that the stock roll can rotate with respect to supporting rod 16, and yet cannot mov~ any great amount laterally to eithex side of the longitudinal axis o~ the dunnage converter mac}1ine during operation o~
the converter to pxoduce the narrow width small size dunnage pad product P, ~ormed ~rom the webs or plies, a, b, and c (Fig. 2) o~ the sheet like stock materlal.
A~orementioned supporting brackets 18 in the embodiInent illustxated, comprise laterally spaced 2S brackets of generally U-shape in side elevation ~Figure 2) with the U ~eing turned on its side and with the aforementioned lower leg ~2 o~ the bracke~ structure a~
each respective side of the converter machine comprising a recess 24 .in which the respective end of the roll supportin~ rod 16 is disposed. As an example o~ the size o roll 1~ of stock material mounted on the converter, the roll may be and pre~erably is o~
approxilnately 12 to 14 inches in diameter or larger.
The machine 10, in the embodiment illustrated, 35 comprises a frame 25 including leg portions 25a, which --` 1325797 may include adjustable means ~not ~hown) as30ciated therewith, for providing for leveling of the dunnage converter mechal1ism with respect to the supporting surface S ~Figure 2)~
Frame ~5 conventionally supports a longitudinally converglng chute member 28 ~Figures 1 and 2) which is shown in phantom lines, for acilitating the illustration, and tl1rough which the stock ma~erial from the stock roll is conventionally adapted to pass in a known manner as it is drawn off the stock roll and passed through ~he conner.ting mecl1anism section 29 of the ~cnown convert r mechal1ism. Such known conver~er mechanism also conventionally includes a three dimensional formin~ frame of t~iangular configuration in plan, which coacts with chute 28. This conventional foxming frame jnot shown) has to be first removed from the converter machine 10, in orde~ to install the funnel-like chute and bar former conversion kit of this in~ention. Reference may be had to aEorementioned U.S.Patent No. 4,750,896 for a detailed ~0 explanation o the usual operation o~ conventional chute member ~8 and forming framQ and connecting mechanism 29 in the converter mechanism. ~owever, chute member 28 is likewi~e not used in the revamped converter mechanism of this invention, to produce the narrow width and small size dunnage pad product o~ tl1is invention. Chute 28 can, however, be either left on the converter,or removed from the converter as revamped for the production of the narrow width small siæe cushioning dunnage product, P, and as will be hereinafter discussed in greater detail.
In accordance with this invention, a conversion kit 30 is provided for converting the lcnown dunnage converter machines of, for instance, the type illustrated in aforementioned patent No. 4,750,~96, to the type of the invention, capable of producing the relatively narrow, small siæe cushioning dunnage pad . , ~
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product P of the invention.
Ths converter kit 30 IFig. 6, 7 and 8) comprises an elongated funnel like chute member 32 (Figure 6 and 7~
wh~ch includes a widened generally oval shaped entrance end 32a and a relatively naxrower exit end 3Zb, again of`
generally oval shape, with the horizontal axis of each oval being of a greater dimension as compared to the vertical axis of the respective oval, and as can be readily seen from Figures 3 and 4 of the patent application drawings.
Funnel chute member 32 preferably has an elongated support strip 34 secured to the underside of the chute member and having a widened head portion 34a~ with means, such as openings 36 therein, ~or conventionally securing the funnel-like chute member 32 in position, interiorly of the aforementioned converging member 2~ of the known converter mechanism, and as illustrated in Figures 1 and 2 of the patent application drawings. For instance, fastener means ~e.g., bolts or screws) can be passed through the aforementioned openings 36 in the head portion 34a of strip 34 and fix the funnel-like chute member 32 ln position to frame 25, so that the exit end ~ :
32b thereo~ is disposed generally adjacent the ex~t end of the chute member 28 (when the latter has not been removed from the converter machine), just upstream from the connecting mechanism 29 of the converter machine, which connecting mechanism will be hereinafter described.
The conversion kit 30 also includes an elongated bar like former member 38 ~Figures 1, 2 and 8) which is recaived interiorly o.f the funnel-like chute member 32 with the downstrealn end of the former member 38 being disposed relatively closely adjacent the exit end 32b of the chute 32 (prefcrably about 1-1/2 inches from the end 32b) and with the upstream end of the former ~ember 38 extending rearwardly out of the entrance end 32a of the -12- i32~797 chute 32, and as bes~ shown in Figures 1 and 2.
Elongated support rods 40, 42 support the former member 38 in posltion in khe chute 32 with the rods 40, 42 being supported on rib 44 of the frame 25 of the converter mechanism, Support rods 40, 42, may be threaded and provided with coacting nuts 46 which enable vertlcal adjustment thereof and thus adjustment of the angular position of the former with respect to the horizont~l and with respec~ to the coacting funnel-li]ce chute member 32.
The forward support rod. ~2 passes through a forrned opening 48 in the conventional converging chute member 28 (if the lat~er is left in the converter mechanism 10 -Fig. 2) and also ~hrough an allgned opening 48a in the auxiliary chute member 32, to be received in secured relationship to the former member 38. Thus~ lt will seen that t~e bar-lilce former member 38 is more or less generally rigidly held in position interiorly of the chute 32, Witll the downstream end of the former member 38 being disposed close to the exit end 32b of ~he chute 32 and occupylng the major portion o~ the transverse dimension of the exit end of chute 32 between the interior defining surfaces thereof. A~s a preferred example, the major axis o the oval exit end 32b of chute 32 may be of approxilnately three inches in dimension, while the minor axis may be approximately 1 ~nch,while the bar-like former member may be and preferably is approximately 2 inches wide by appxoximately 1 inch in thicknes~. The downstream end o~ the bar former is adapted to engage the superi1nposed plies of stock material in generally tensioned condition a~ the plies are pulled by the connecting means 29 past the bar former and out of exit 32b of the chute 32. The corners of the bar former at said downstream end may be broken to aid in preventing tearin~ of the plies of stock materialO Nuts 132~797 on forward support rod also coact w~th chute 32 to support the latter in posltion in the converter mechani~m.
As lllustrated in detall in Flgs. 8 and 9, the former member 38 may include elongated through ~lots 52 therein through which extend the respective support rod 40, 42~
thus provlding for some lengthwise adjustment of the position of the former member relative to the exit end oE
coacting chute 32. Also, as shown in Fig. 9 slant washers 54 may be used in conjunction wlth nuts 56 on the support rods (both forward and rearward) for releaslbly securing the lengthwise position of the former member 38 relative to chute 32, and in angular relation to the horizontal. The downstrealn end of the former ~ar is pre~erably positioned about 1/4 inch from the deflning bottom surface of ~he chute, while the vertical distance ~etween the underside o the bar former and the bottom surface of the chute 32 at the entrance end 32a thereof is preferably about one and one-fourth inches.
The separating mechanism 60 which is at the forward end of the converter machine receives the plies or webs of sheet like ~tock materi~l from the multi-ply stock roll 12, and separates the plies into individual plies or webs of stock material, prior to their passing beneath the bar former member 38 and into the funnel-like chute 25 member 3Z. Separatin~ means 60 comprises a plurality of pre~erably rotatable bar like elements 62a, 62b and 62c about which is adapted to pass a respective web of the stock material from the rotatable stock roll 12. Also disposed outwardly from the separatin~ mechanism 60 and supported on the upper arms of the bracket 18 is a further bar-like member 64 which in the embodiment illustrated is a rotatable roller mounted at its ends on the spaced upper arlns of U brac]cets 18. Roller 64 pro~ides a non varyin~ point of entry of the plies of 132~797 sheet like stock material from the stock roll a~ they are pulled into the dunna~e producing mechanism toward the connecking means 29 irresuective o~ the diameter of th~
stoc~ roll, which of course, continually varies as it is u~ed up. Re~erence may be had to the aforementioned U.S. Patent No. 4,750,896 for a more detailed description and explanation of the operation of the separating mechanism on associated constant entry roller 64.
Connecting mechanism 29, in the embodiment illustrated comprises generally loosely meshed vertically arranged gear-lilce or meshing tooth members 65, 65a which are sotatably mounted by means of a respective shaft~
Shaft 66 of the upper gear 65is preferably arranged with the end of the shaft being mounted in slatte~ bracket frames (not sllown) on frame 25, with springs being provided coacting witll the respective end of the shaft to urge tle shaft 66 and associated gear 65 downwardly toward the underlying gear member 65a, thus providing a somewhat floating but downwardly biased support for the top gear. Such an arrangement provides for automatically varying the spacing between the gear teeth ln the event of varyin~ amounts or thickness oE s~ock material attempting to pass between the ~ears during the connectin~ operation. The coining gears in known converter mechanisms, of this type and khe type of aforementioned U.S. Patent No. 4,750,896 are about 1-1/1 inches in width, and thus the Ina~ or portion of the produced -relatively narrow pad-like produc~ is compressed in a direction transverse of the produced dunnage pad as the coining operation proceeds.
Reference may be had to aforementioned U.S. Patent No. 4,750,896 for a more detailed description of the ba~ic skructural 35 arrangem~nt o~ ~h~ collver~er maalline I an~ mealls ~or .. . .
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132~797 drlving the rotatable connecting means 29 thereo~.
Disposed downstream ~rom the rotatable gear connecting means 29 is a tunnel member 68 on the known converter machine and through which the narrow pad-llke product produced by the converter machine passes as it is emitted from the connectlng means 29 prlor to emission o~
the pad-like cushioning dunnage product through the exit opening 70 in the co~verter mechanism. Powered cutter means 71 is preferably provided for severlng the pad-li]ce product into selected lengths as it is emitted frorn the converter, and in the usual manner.
As the sheet like stock material ~rom roll 12 is passed through the funnel-like chute member 32, the inwardly rolled edges of the stock material are disposed in generally lateral, abutting relationship, as they emerge ~rom the exit end 32b o~ the chute and then they are colnpressed or "coined" and joined together as a~orementioned, by the geared connecting mechanism ~9, resulting in spaced, coined connecting seckions 72 spaced lengthwise of the produced dunnage pad P, and as illustrated in Figure 5. The lateral extexlor edge portions 74 of the pad are of ~enerally non- compressed or non-~oined condition, and thus have a somewhat greater resillency or "give" as compared to the central compressed section 76 of the pad, and may be of hetween approximately one to one and a quarter inch tl~ickness.
The central generally compressed section 76 of the pad extends ~or the major portion of the transverse width of the pad, with only relatively small areas being provided on the lateral edges of the pad that are in the aforedescribed non-compressed condition. As the pad exits from the exit opening in the dunnage converter, lt passes by the aforementioned cutter mechanism 71 which when actuated by a wor]cman, severs the produced pad-like dunnage product into selected lengths ~or use as packing, ~32~97 edge cushioning, furniture wrapping, or the like.
From the ~oregoing descript.ion and accompanying drawings, lt will be seen that the invention provides a novel converter mechanism which has been adapted from producing full size pad like dunnage product, to one that produces relatively narrow width small size cushioning dunnage product from sheet like stock material, such as for instance paper, and wherein the c~nverter mechanism has been expeditiously revamped by means of a conversion k~t comprising a funnel-like chute member and a coacting elongated bar lilce former member, which operate to cause inward rolling of the lateral edges of the sheet like stock material as it is pulled from a mul~i-ply stock roll, after which the rolled edge stock matarial passes through a connector or "coining" means, wherein the abuttlng lateral rolled edge portions are connected together, to hold the produced narrow width pad~like dunnage product in its pad like form.
The invention also provides a novel arrangement of produced dunnage product in pad like form which is of a relatively narrower width and ~mall size as compared to full size dunnage pad product produced on known dunnage converter mec'nanism, and which is especially adapked for use in the packaging of small parts and for cushioning edge~ and parts of articles such as furniture or the like, during the shipment thereof.
The invention also provides a novel method for the production of relatively narrow pad like dunnaye product by utilization of a bax like former member which occupies the ma~or portion of the transverse dimensional space between the interior surfaces defining the exit end o an associated funnel-like chut~ member so that ~he webs or plies of s~ock mate.ri~l being pulled from the stock roll . ara ~orced into the limited unobstructed areas between the downstream end of the former member and the interior defining surfaces of the exlt end of the funnel-like chute member, thus producing the relatlvely narrow small size dunnage pad like product.
The ter~s and expression~ which have been used are used as terms of description and not o~ llmitation and there is no intention in the use of such terms and expressions o excludln~ any equivalents of any of the ., ~eatures shown or described, or portions thereof, and it ls recogni~ed that various modif~cations are possible 10 within the scope of the invention claimed~ -:
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Thi~ invent~o~ relates in general to dunnage converter mechanism ~or producing dunnage product of pad-like form from sheet-like stock material and more particularly relates to a dunna~e converter for producin~ from sheet-like stock material, such as papex, a continuous strip of resilient, relatively narrow and small size pad-like dunnage product, which can be expeditiously used for cushioning and packaging relatively small parts, as well as for use in protecting the edges of products during shiplnent thereof, such as for instance the edges of furnitur~e including the arms and leg~ thereof, and the like.
With this invention, known converter mech~nism for i.
pr~ducing relatively wide, pad-lik2 cushioning dunnage produc~ is able to be expeditiously converted in the ~ield into a converter mechanism of the present invention for produclng relatively narrow pad-like cushioning dunnage product, and by means of the utillza~ion of a novel conversion kit, which includes a .funnel-like chute member and an elongated, bar-like former ~nembert which is mounted in the exist~ng converter mechani~m, and which changes the size o~ the produced pad like cu~hioning dunnage product. Also the multi-ply stock roll utilized in this invention for providing the sheet-like ~tock makerial to form the cushioning dunnage product, is of a materially lesser width as compared to that used in the aforelnentioned kno~n cushioning dunnage converter mechanisms, and in this connection, positioning elements are provided coacting with the lesser width stock roll, for properly maintaining ths position of the lesser width stock roll on the revamped converter mechanism.
132~797 BACKGROUND OF THE INVENTION
Cu~hioning dunnage producing mechanism for producing a resilient pad-like cushioning dunnage product having lateral pillow like portions centrally connected as by 5 colning andtor a~hesive means, are ~nown in the art.
~pplicant's U.S. Patent No. 4,750,896, issued June 14, 1988 in the names o~ ~nthony J. Komaransky and Raymond Q. Armington and entitled Method and Mechanism ~or Producing Cushioning Dunnage Product~
10 discloses a cushionin~ dunnage converter mechanism of the general type as that to whicll the present invention is dlrected. Such prior art converter mechanism includes a funnel-like chute membex which coacts with a triangular shape tin plan) forming ~rame, for forming the 15 sheets of stock material for a multi-ply stock roll into rolled con~i~uratlon prior to their passing into and through coacting rotatable connecting gears, which "coin"
the rolled edge stock material, and produce a full or conventional size pad-like cushioning dunnage product of 20 about 8 to 10 inches in wldtll, having laterally arranged, resilient plllow llke por~ions, which are connected centrally o~ the pad like dunnage product, running lengthwise thereof.
There are other prior art patents disclosing dunnage 25 producing mechanism and methods ~or producing a t resilient cushioning dunnage product Qf the general pad-like type of abovementioned U.S. Patent No. 4,750,~96.
U.S. Patent ~,026,198 to Gary W. Ottavaino dated May 31, 1977 and entitled Cushioning Dunnage Mechanisml Transfer 30 Cart Therefor and Method, discloses a cusllioning dunnage producing converter mechanism which produces a ~ull size resllient pad like dunnage product comprising lateral, resilient, pillow-like portions connected along the central portion of the pad runnin~ lengthwise thereof, 35 together with methods and apparatus for produc~n~ the same.
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` -4~ 1325797 U.S. Patent 3,655,500 dated Aprll 11, 1972 to G. R.
Johnson and entitled ~ Resilient Cusllionin~ Dunnage Product for Use in Packaging and Packlng, and U.S~
Patent, 4,109,040, dated August 22, 197~ to Gary WO
Ottavaino and entitled Cushioning Dunnage Product Produced from Cushionillg Dunnage Mechanism, disclose full size resilient pad like dunnage producks comprising lateral, resilient, pillow-like por~ions connected along the central portion of the pad running lengthwise thereof.
Applicant's Canadian Patent No. 1,243/300, issued November 1, 1988 in the name of Gary W. Ottavaino, and entitled ~echanism and Method for Producing Cushioning Dunnage, discloses a relatively light weight cushionin~ dunnage product of the a~orementioned resilient pad like ~orm, but of the same yeneral width as those aforediscussed, together with a metllod and apparatus ~or producing the same.
The prior art converter mechallisms and the ~ull size pad like cushioning dunnage product produced ~hereby, are not the same as the narrow pad like cusllioning dunnage product produced on a converter mechanlsm u~ili2ing the conversion kit provided by the present inven~ion. The relatively narrow and small siæe pad like product of this invention ls m~re exped~tiously utilizable ~or packagin~ and wrapping small parts, and may also be more approprlately utilized in certain cushioning situations wherein the larger size of cushioning dunnage pad i5 not conveniently utilizable or adaptable, such as for instance in protecting and cushionlng sharp edges of articles, such as furniture and the lilce and/or for furniture leg and/or arm wrap, etc. during shipmen~ of the articles.
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_5_ 132~797 SUMM~RY OF THE INVENTION
The present invention provlde~ a no~el, pad like cushioning dunnage product, and method for the production thereof from sheet-like stock material, such as for lnstance paper, with the machine produced product comprising a relatively narrow, deformable pad lilce cushioning article between approximately 3-lJ2 inches to approximately 4 inches in width, and appxoximately 1 to 1-1/4 inches ln thickness, at its lateral edge portions, with the cushioning article compri~ing lateral rolled edge portlons of the sheet like stock ma~erial and which are ~oined generally centrally of tlle pad-like cusllioning article lenythwise thereo~, by transversely extending coined portions o~ the pad like article, and with the article possessing a density o~ approximately one pound per cubic foot.
The relatively narrow and small size pad like cushioning article i5 especially useful in the packaging of small parts, and is adapted for use in other cushioning situations whereln larger size pad-like cushioning product is not sultable or readlly adaptable. The converter mechanism or machine from whlch the narrow width cushioning article of the present invention is produced, may be generally similar to that disclosed in the aforementioned prior U~S. Paten~
4,750,896, except that such converter mechanism has been revamped by means of the conversion kit of this invention, for production of the narrower and smaller size o~ cushionin~ dunnage pad product, and as will be hereinafter discussed in detail.
The aforementioned conversion kit o~ this invent.ion comprises a ~unnel~like chute member and an elongated bar-like former mernber which i~ adapted to coact with the .. ~, ' ., .
-6- ~ ~25797 chute member in a generally known but revamped type of converter mechanism of the general type for instance of aforementioned U.S.Patent No. 4,7~0,&96together with utilization of a shorter width of multi-ply stock roll, to provide for the production of the narxower width and smaller size cushioning dunnage pad~like product of this invention.
Accordingly, an object of this invention is to provide a novel, relatively small size and narrow width cushioning dunnage product of pad-like form, for use as packing material and the like, especially useful in the packaging of small parts.
Another object of the invention is to provide a conversion kit which includes a funnel-like chute member and an elongated bar-like former member which is adapted for removable installation in a known type of converter mechanism, f~r enabling production of the aforementioned smaller size and narrow width cushioning dunnage product, utilizing the generally known type of converter mechanism, but as revamped by the conversion kit apparatus.
A still further object of the invention is to provide a conversion ket of the aforementioned type which includes a funnel-like chu-te member and a coacting elongated bar-like former member, which can be utilized in the field to convert a known dunnage producing converter mechanism, which conventionally produces full size cushioning dunnage product in pad-like form, into one that produces the relatively small size, narrow width cushioning dunnage product of the invention.
A still further object of the invention is to provide a novel method for the production of pad-like cushioning dunnage product of relatively small size and narrow width, which can be expeditiously utilized in the packaging of small parts, and for other cushioning uses _7_ 132~797 for which largQr or full siæe size cu~hioning dunnage pad product produced on a cushioning dunnage converter of known ~ype, is not readily adaptable for.
Other objects and advantages of the lnvention will ba S apparent froM the following description taken in con~unction wlth the accompanying drawings herein.
DESCRIPTION OF THE D~AWINGS
Figure 1 is a broken, partially sectioned, top plan view of a known dunnage converter mechanism which has been revamped by use of the conversion kit of the present invention, into a dunnage converter capable of producing the relatively naxrow small size pad like cushioning dunnage product of the invention.
Figure 2 is a partially sectioned, side elevational lS view of the mechanism of Figure 1.
Figure 3 is a partially broken, end elevational view of the mechanism of Figures 1 and 2, taken from the right hand or product exit end thereof.
Figure 4 is an end elevatlonal view of the mechani~m of Figures 1 and 2 taken from the le~t hand or s~ock material entry end thereof.
Figure 5 is a broken, fragmentary, end and perspective ill~stration of ~he relatively narrow small size pad like dunnage product produced on the revamped dunnage producin~ converter mechanism of Figs. 1-4.
Figure 6 is a top plan view o~ the funnel-like chute member of the conversion kit of ~he invention, which is adapted for installation into a known converter mechanisl~ for revamping it to produce ~he relatively narrow small size cushioning dunnage product of the invention.
Figure 7 is a side elevational view o~ the funnel member of Figure 6, taken from the right hand side thereof.
~325797 Figure 8 is a generally perspective illus~ration of the elongated bar like ormer member which is adapted for coaction with the funnel chute member o~ the conversion kit, when installed in a known converter mechanism1 the supporting rods for the ~ormer member are shown in bro}cen phantom linas; and Figure 9 is a fragmentary,side elevational view of the rearward end portion of the ~ormer member of Fig. 8 illustrating the use o~ slant wasllers with the associated support rod, for aiding in positioning o~ the ~ormer member in the converter mecl~anism.
DESCRIPTION OF PREF~RRED EMBODIMENT
Referring now again to the draw~nys, there is illustrated a dunnage producing machine 10 which is adapted to utilize a single, multi-ply stock roll 12 of sheet like stock material (such as ~or instance 3 sheets o~ 30 pound kraft paper) which are rolled into single roll form. In khe embodiment of stock roll illustrated in Figures 1 and 2, the plies of the stock roll are o~
equal width and comprise 3 plies disposed in roll form, for rotatable installation on tha dunnage producing converter mechanism 10.
The s~ock roll 12, in the machine embodiment illustrated, is approximately 15 inches ~n width, ~i.e., ln a direction transverse of machlne 10) as compared to a conventional stock roll of approximately 30 inch width, ~s conve~tionally used on dunnage converter mechanism of the ~eneral type illustrated and described for instance in aforementioned U.SO Patent No. 4,750,896.
Stock roll 12 in this embodlment, comprises a hollow core 14 (Fig. 4) of generally cylindrical tubular configuration on which the three superimposed webs or sheets of papar s~ock m~terial are wound. Stock roll 12 , ' .. ~
g is adapted to ~e mounted on a supportlng rod 16 extendlng relatively loosely through the core 14 o~ the roll, for rotation of the stock roll 12 and core 14 relative to the supporting bracket framework structure 18 o~ the converter Inachine 10. As khe stock material is drawn from the roll 12 into the dunnage converter machine 10, the roll 12 rotates in a clockwlse direction as viewed in Fig. 2.
In order to posltion the lesser width s~ock roll 12 on the supporting rod 16 generally centrally o~ the longitudinal axis of the dunnage converter machine~ a pair of sleeves 20 are slipped over the respective end o~
the stock roll supporting rod 16 and extend from the corresponding end o~ the stock roll to th~ respective arm lS ~2 o~ each supporting bracket 18 for the stock roll.
Thus, it will be seen that the stock roll can rotate with respect to supporting rod 16, and yet cannot mov~ any great amount laterally to eithex side of the longitudinal axis o~ the dunnage converter mac}1ine during operation o~
the converter to pxoduce the narrow width small size dunnage pad product P, ~ormed ~rom the webs or plies, a, b, and c (Fig. 2) o~ the sheet like stock materlal.
A~orementioned supporting brackets 18 in the embodiInent illustxated, comprise laterally spaced 2S brackets of generally U-shape in side elevation ~Figure 2) with the U ~eing turned on its side and with the aforementioned lower leg ~2 o~ the bracke~ structure a~
each respective side of the converter machine comprising a recess 24 .in which the respective end of the roll supportin~ rod 16 is disposed. As an example o~ the size o roll 1~ of stock material mounted on the converter, the roll may be and pre~erably is o~
approxilnately 12 to 14 inches in diameter or larger.
The machine 10, in the embodiment illustrated, 35 comprises a frame 25 including leg portions 25a, which --` 1325797 may include adjustable means ~not ~hown) as30ciated therewith, for providing for leveling of the dunnage converter mechal1ism with respect to the supporting surface S ~Figure 2)~
Frame ~5 conventionally supports a longitudinally converglng chute member 28 ~Figures 1 and 2) which is shown in phantom lines, for acilitating the illustration, and tl1rough which the stock ma~erial from the stock roll is conventionally adapted to pass in a known manner as it is drawn off the stock roll and passed through ~he conner.ting mecl1anism section 29 of the ~cnown convert r mechal1ism. Such known conver~er mechanism also conventionally includes a three dimensional formin~ frame of t~iangular configuration in plan, which coacts with chute 28. This conventional foxming frame jnot shown) has to be first removed from the converter machine 10, in orde~ to install the funnel-like chute and bar former conversion kit of this in~ention. Reference may be had to aEorementioned U.S.Patent No. 4,750,896 for a detailed ~0 explanation o the usual operation o~ conventional chute member ~8 and forming framQ and connecting mechanism 29 in the converter mechanism. ~owever, chute member 28 is likewi~e not used in the revamped converter mechanism of this invention, to produce the narrow width and small size dunnage pad product o~ tl1is invention. Chute 28 can, however, be either left on the converter,or removed from the converter as revamped for the production of the narrow width small siæe cushioning dunnage product, P, and as will be hereinafter discussed in greater detail.
In accordance with this invention, a conversion kit 30 is provided for converting the lcnown dunnage converter machines of, for instance, the type illustrated in aforementioned patent No. 4,750,~96, to the type of the invention, capable of producing the relatively narrow, small siæe cushioning dunnage pad . , ~
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product P of the invention.
Ths converter kit 30 IFig. 6, 7 and 8) comprises an elongated funnel like chute member 32 (Figure 6 and 7~
wh~ch includes a widened generally oval shaped entrance end 32a and a relatively naxrower exit end 3Zb, again of`
generally oval shape, with the horizontal axis of each oval being of a greater dimension as compared to the vertical axis of the respective oval, and as can be readily seen from Figures 3 and 4 of the patent application drawings.
Funnel chute member 32 preferably has an elongated support strip 34 secured to the underside of the chute member and having a widened head portion 34a~ with means, such as openings 36 therein, ~or conventionally securing the funnel-like chute member 32 in position, interiorly of the aforementioned converging member 2~ of the known converter mechanism, and as illustrated in Figures 1 and 2 of the patent application drawings. For instance, fastener means ~e.g., bolts or screws) can be passed through the aforementioned openings 36 in the head portion 34a of strip 34 and fix the funnel-like chute member 32 ln position to frame 25, so that the exit end ~ :
32b thereo~ is disposed generally adjacent the ex~t end of the chute member 28 (when the latter has not been removed from the converter machine), just upstream from the connecting mechanism 29 of the converter machine, which connecting mechanism will be hereinafter described.
The conversion kit 30 also includes an elongated bar like former member 38 ~Figures 1, 2 and 8) which is recaived interiorly o.f the funnel-like chute member 32 with the downstrealn end of the former member 38 being disposed relatively closely adjacent the exit end 32b of the chute 32 (prefcrably about 1-1/2 inches from the end 32b) and with the upstream end of the former ~ember 38 extending rearwardly out of the entrance end 32a of the -12- i32~797 chute 32, and as bes~ shown in Figures 1 and 2.
Elongated support rods 40, 42 support the former member 38 in posltion in khe chute 32 with the rods 40, 42 being supported on rib 44 of the frame 25 of the converter mechanism, Support rods 40, 42, may be threaded and provided with coacting nuts 46 which enable vertlcal adjustment thereof and thus adjustment of the angular position of the former with respect to the horizont~l and with respec~ to the coacting funnel-li]ce chute member 32.
The forward support rod. ~2 passes through a forrned opening 48 in the conventional converging chute member 28 (if the lat~er is left in the converter mechanism 10 -Fig. 2) and also ~hrough an allgned opening 48a in the auxiliary chute member 32, to be received in secured relationship to the former member 38. Thus~ lt will seen that t~e bar-lilce former member 38 is more or less generally rigidly held in position interiorly of the chute 32, Witll the downstream end of the former member 38 being disposed close to the exit end 32b of ~he chute 32 and occupylng the major portion o~ the transverse dimension of the exit end of chute 32 between the interior defining surfaces thereof. A~s a preferred example, the major axis o the oval exit end 32b of chute 32 may be of approxilnately three inches in dimension, while the minor axis may be approximately 1 ~nch,while the bar-like former member may be and preferably is approximately 2 inches wide by appxoximately 1 inch in thicknes~. The downstream end o~ the bar former is adapted to engage the superi1nposed plies of stock material in generally tensioned condition a~ the plies are pulled by the connecting means 29 past the bar former and out of exit 32b of the chute 32. The corners of the bar former at said downstream end may be broken to aid in preventing tearin~ of the plies of stock materialO Nuts 132~797 on forward support rod also coact w~th chute 32 to support the latter in posltion in the converter mechani~m.
As lllustrated in detall in Flgs. 8 and 9, the former member 38 may include elongated through ~lots 52 therein through which extend the respective support rod 40, 42~
thus provlding for some lengthwise adjustment of the position of the former member relative to the exit end oE
coacting chute 32. Also, as shown in Fig. 9 slant washers 54 may be used in conjunction wlth nuts 56 on the support rods (both forward and rearward) for releaslbly securing the lengthwise position of the former member 38 relative to chute 32, and in angular relation to the horizontal. The downstrealn end of the former ~ar is pre~erably positioned about 1/4 inch from the deflning bottom surface of ~he chute, while the vertical distance ~etween the underside o the bar former and the bottom surface of the chute 32 at the entrance end 32a thereof is preferably about one and one-fourth inches.
The separating mechanism 60 which is at the forward end of the converter machine receives the plies or webs of sheet like ~tock materi~l from the multi-ply stock roll 12, and separates the plies into individual plies or webs of stock material, prior to their passing beneath the bar former member 38 and into the funnel-like chute 25 member 3Z. Separatin~ means 60 comprises a plurality of pre~erably rotatable bar like elements 62a, 62b and 62c about which is adapted to pass a respective web of the stock material from the rotatable stock roll 12. Also disposed outwardly from the separatin~ mechanism 60 and supported on the upper arms of the bracket 18 is a further bar-like member 64 which in the embodiment illustrated is a rotatable roller mounted at its ends on the spaced upper arlns of U brac]cets 18. Roller 64 pro~ides a non varyin~ point of entry of the plies of 132~797 sheet like stock material from the stock roll a~ they are pulled into the dunna~e producing mechanism toward the connecking means 29 irresuective o~ the diameter of th~
stoc~ roll, which of course, continually varies as it is u~ed up. Re~erence may be had to the aforementioned U.S. Patent No. 4,750,896 for a more detailed description and explanation of the operation of the separating mechanism on associated constant entry roller 64.
Connecting mechanism 29, in the embodiment illustrated comprises generally loosely meshed vertically arranged gear-lilce or meshing tooth members 65, 65a which are sotatably mounted by means of a respective shaft~
Shaft 66 of the upper gear 65is preferably arranged with the end of the shaft being mounted in slatte~ bracket frames (not sllown) on frame 25, with springs being provided coacting witll the respective end of the shaft to urge tle shaft 66 and associated gear 65 downwardly toward the underlying gear member 65a, thus providing a somewhat floating but downwardly biased support for the top gear. Such an arrangement provides for automatically varying the spacing between the gear teeth ln the event of varyin~ amounts or thickness oE s~ock material attempting to pass between the ~ears during the connectin~ operation. The coining gears in known converter mechanisms, of this type and khe type of aforementioned U.S. Patent No. 4,750,896 are about 1-1/1 inches in width, and thus the Ina~ or portion of the produced -relatively narrow pad-like produc~ is compressed in a direction transverse of the produced dunnage pad as the coining operation proceeds.
Reference may be had to aforementioned U.S. Patent No. 4,750,896 for a more detailed description of the ba~ic skructural 35 arrangem~nt o~ ~h~ collver~er maalline I an~ mealls ~or .. . .
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132~797 drlving the rotatable connecting means 29 thereo~.
Disposed downstream ~rom the rotatable gear connecting means 29 is a tunnel member 68 on the known converter machine and through which the narrow pad-llke product produced by the converter machine passes as it is emitted from the connectlng means 29 prlor to emission o~
the pad-like cushioning dunnage product through the exit opening 70 in the co~verter mechanism. Powered cutter means 71 is preferably provided for severlng the pad-li]ce product into selected lengths as it is emitted frorn the converter, and in the usual manner.
As the sheet like stock material ~rom roll 12 is passed through the funnel-like chute member 32, the inwardly rolled edges of the stock material are disposed in generally lateral, abutting relationship, as they emerge ~rom the exit end 32b o~ the chute and then they are colnpressed or "coined" and joined together as a~orementioned, by the geared connecting mechanism ~9, resulting in spaced, coined connecting seckions 72 spaced lengthwise of the produced dunnage pad P, and as illustrated in Figure 5. The lateral extexlor edge portions 74 of the pad are of ~enerally non- compressed or non-~oined condition, and thus have a somewhat greater resillency or "give" as compared to the central compressed section 76 of the pad, and may be of hetween approximately one to one and a quarter inch tl~ickness.
The central generally compressed section 76 of the pad extends ~or the major portion of the transverse width of the pad, with only relatively small areas being provided on the lateral edges of the pad that are in the aforedescribed non-compressed condition. As the pad exits from the exit opening in the dunnage converter, lt passes by the aforementioned cutter mechanism 71 which when actuated by a wor]cman, severs the produced pad-like dunnage product into selected lengths ~or use as packing, ~32~97 edge cushioning, furniture wrapping, or the like.
From the ~oregoing descript.ion and accompanying drawings, lt will be seen that the invention provides a novel converter mechanism which has been adapted from producing full size pad like dunnage product, to one that produces relatively narrow width small size cushioning dunnage product from sheet like stock material, such as for instance paper, and wherein the c~nverter mechanism has been expeditiously revamped by means of a conversion k~t comprising a funnel-like chute member and a coacting elongated bar lilce former member, which operate to cause inward rolling of the lateral edges of the sheet like stock material as it is pulled from a mul~i-ply stock roll, after which the rolled edge stock matarial passes through a connector or "coining" means, wherein the abuttlng lateral rolled edge portions are connected together, to hold the produced narrow width pad~like dunnage product in its pad like form.
The invention also provides a novel arrangement of produced dunnage product in pad like form which is of a relatively narrower width and ~mall size as compared to full size dunnage pad product produced on known dunnage converter mec'nanism, and which is especially adapked for use in the packaging of small parts and for cushioning edge~ and parts of articles such as furniture or the like, during the shipment thereof.
The invention also provides a novel method for the production of relatively narrow pad like dunnaye product by utilization of a bax like former member which occupies the ma~or portion of the transverse dimensional space between the interior surfaces defining the exit end o an associated funnel-like chut~ member so that ~he webs or plies of s~ock mate.ri~l being pulled from the stock roll . ara ~orced into the limited unobstructed areas between the downstream end of the former member and the interior defining surfaces of the exlt end of the funnel-like chute member, thus producing the relatlvely narrow small size dunnage pad like product.
The ter~s and expression~ which have been used are used as terms of description and not o~ llmitation and there is no intention in the use of such terms and expressions o excludln~ any equivalents of any of the ., ~eatures shown or described, or portions thereof, and it ls recogni~ed that various modif~cations are possible 10 within the scope of the invention claimed~ -:
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Claims (13)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A resilient narrow width cushioning product comprising a deformable pad article for packaging of small parts or protecting edges of products to be packaged which is machine formed from sheet material, such as for instance paper, the lateral edges of which have initially been rolled inwardly toward one another into generally abutting relationship, said article including means comprising transversely extending coined portions of said article spaced relative to one another lengthwise of said article, and connecting non-coined lateral rolled edge portions of said article together, said coined portions extending transversely of said article toward opposite sides of the lengthwise axis of said article, for a major portion of the transverse dimension of said article, but terminating adjacent said lateral non-coined edge portions, said article possessing a density of approximately one pound per cubic foot, and being between approximately three and one-half inches to approximately four inches in width and having a thickness of approximately one to one and one-fourth inches at said non-coined edge portions and a lesser thickness at said coined portions.
2. A product in accordance with claim 1, wherein said article is formed of three individual webs of paper sheet material disposed in generally superimposed relation prior to said inward rolling of the lateral edges of said webs.
3. A product in accordance with claim 2, wherein each of said webs consists of 30 pound kraft paper of approximately 15 inches in width, with said superimposed webs being disposed in roll form prior to said inward rolling of the lateral edges thereof.
4. A product in accordance with claim 1, wherein the central section of the pad-like article in a lengthwise direction thereof has a greater density as compared to the lateral non-coined edge portions of the pad.
5. In a method of producing cushioning dunnage product in pad-like form from sheet-like stock material comprising, providing a predetermined width multi-ply roll of the sheet-like stock material and mounting it for rotation about its axis of curvature, pulling the plies of the sheet-like material from the roll during rotation of the latter and rolling the lateral edges of the plies inwardly by means of a funnel-like chute member having an inlet end and an outlet end, with the inlet end being the larger of said ends, and forcing the rolled edges of the plies inwardly into a pad-like configuration by means of said funnel-like chute member and a coacting elongated bar-like former member disposed interiorly of said funnel-like chute member and extending longitudinally relative thereto, so that the rolled edges of the sheet-like stock material are disposed in generally abutting condition at said outlet end, and then connecting the rolled edge portions together by coining thereof along the juncture thereof and transversely of the pad-like article, to form a produced unitary pad-like dunnage product of a width within a range of approximately three and one-half to approximately four inches, and having a thickness at the lateral edge portions thereof of approximately one to one and a fourth inches.
6. A method in accordance with claim 5, including the step of providing three plies of said sheet-like material in said roll form, orienting the latter into generally engaged surface-to-surface superimposed relation during said pulling of the superimposed plies lengthwise as a unit through said funnel-like member and from said inlet end through said outlet end, and into generally tensioned engagement with one another, and wherein the step of rolling the lateral edges of the plies inwardly comprises utilization of said former extending generally lengthwise of said funnel-like chute member along the vertical longitudinal center plane thereof, and positioning the downstream end of said former generally adjacent the exit end of said funnel-like chute member so that the last mentioned former end occupies a major portion of the transverse interior dimension of said funnel-like chute member at said last mentioned end.
7. A method in accordance with claim 6, including shearing the formed pad-like article transversely thereof into selected length.
8. A method in accordance with claim 5, including positioning the upstream end of said former at an upwardly tipped angle with respect to the horizontal, and tilting the downstream end of said former downwardly with respect to the horizontal.
9. A converter mechanism for taking paper in stock roll form and converting it into a narrow width and small size pad-like cushioning product for use for instance, in packaging and comprising lateral juxtaposed portions which have been coined transversely thereof to maintain said portions in generally connected relation, and forming a pad-like product, said converter mechanism comprising a frame, means on said frame for causing inwardly rolling of the lateral edges of the sheet-like stock material into generally rolled form, said means including a longitudinally extending converging funnel-like chute member and a coacting former member extending lengthwise and interiorly of said chute member, the latter including a widened entrance end portion and relatively narrower exit end portion, means for rotatably mounting a multi-ply stock roll of the sheet-like material, for supplying the latter to the first mentioned means, and coining means on said frame disposed downstream from said chute member and adapted to receive the rolled edge sheet-like stock material between the bite thereof and operable to connect the same into pad-like cushioning dunnage product form, said coining means being operable to pull the sheet-like stock material from the stock roll through said chute member and past said former, said former comprising an elongated generally rectangular shaped bar having its forward end positioned generally adjacent said exit end of said chute member and its rearward end extending rearwardly of said entrance end portion of said chute member.
10. A converter mechanism in accordance with claim 9, wherein said exit end portion of said chute is of oval configuration with the major axis of said oval configuration extending transverse of said mechanism and disposed in a generally horizontal plane, the major transverse dimension of said former extending transverse of said mechanism and being disposed in a generally horizontal plane, and with the downstream end of said former occupying the major portion of the interior area of said chute at said downstream end.
11. A converter mechanism in accordance with claim 10, wherein said former is tilted with respect to the horizontal with the upstream end of said former being in a raised condition with respect to the horizontal.
12. A converter mechanism in accordance with claim 11, including means providing for the adjustment of the position of said former relative to said chute in the lengthwise direction therefor.
13. A converter mechanism in accordance with claim 11, including slant washer means coacting with said former for aiding in retaining said former in said tilted position of said former relative to the horizontal.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/140,734 US4884999A (en) | 1988-01-04 | 1988-01-04 | Dunnage converter for producing narrow width cushioning pad product, conversion kit thereof, and method |
| US140,734 | 1988-01-04 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1325797C true CA1325797C (en) | 1994-01-04 |
Family
ID=22492563
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000584763A Expired - Fee Related CA1325797C (en) | 1988-01-04 | 1988-12-01 | Dunnage converter for producing narrow width cushioning pad product, conversion kit therefor, and method |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US4884999A (en) |
| CA (1) | CA1325797C (en) |
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-
1988
- 1988-01-04 US US07/140,734 patent/US4884999A/en not_active Expired - Lifetime
- 1988-12-01 CA CA000584763A patent/CA1325797C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| US4884999A (en) | 1989-12-05 |
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