Cushioning dunnage mechanism, transfer cart therefor, and method

Abstract

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

This invention relates in general to mechanism for producing packing material or cushioning dunnage as it is known in the art, and more particularly to a dunnage producing mechanism for the production of a continuous, highly resilient, pad-like dunnage product from sheet-like stock material disposed 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 from the dunnage producing machine. The invention also relates to a novel method of producing and transferring the pad-like cushioning dunnage product.

BACKGROUND OF THE INVENTION

In U.S. Pat. No. 3,799,039 issued Mar. 26, 1974 to George R. Johnson and entitled "Cushioning Dunnage Mechanism and Method" there is disclosed a cushioning dunnage producing mechanism of the general type of the present invention, for producing a generally similar pad-like cushioning dunnage product. While such prior art mechanism 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 material into the crumpler section of the machine. Tearing of the stock material generally necessitated shutting down of the machine and reinserting non-torn portions of the webs from the stock roll into the crumpler mechanism, so that a high quality dunnage pad could be produced in the mechanism. Moreover, with the arrangement disclosed in the U.S. Pat. No. 3,799,039, the dunnage material produced was generally used at the location of or in the immediate vicinity of the dunnage producing machine, and the transfer of the dunnage pad material to another location was not too convenient.

SUMMARY OF THE INVENTION

The present invention provides a novel dunnage producing mechanism for producing from sheet-like stock material, such as paper, a pad-like cushioning dunnage product, and wherein the machine is an improved arrangement of the dunnage producing machine of the aforementioned U.S. Pat. No. 3,799,039. Moreover, the invention provides a dunnage producing mechanism of the above described type which includes a transfer vehicle for use in conjunction with the dunnage producing machine, for expeditiously providing for transfer of a preselected amount of the pad-like dunnage material from the location of the machine to a location distant from the dunnage producing machine, and in a manner wherein the dunnage pad material may be expeditiously transferred from the producing machine to the transfer vehicle.

Accordingly, an object of the invention is to provide a novel compact mechanism for producing dunnage packing material.

Another object of the invention is to provide a mechanism of the latter type which utilizes a multi-ply roll of stock material rotatably mounted on the mechanism and wherein the axis of rotation of the paper stock material roll is so located so that there is reduced tendency for tearing of the sheets of stock material as they pass through the dunnage machine to be formed into a continuous lightweight cushioning dunnage pad.

Another object of the invention is to provide a transfer vehicle in conjunction with a mechanism of the above type for transferring selected amounts of the dunnage pad produced from the machine to a location distant from the machine, in an expeditious manner.

A still further object of the invention is to provide a dunnage producing mechanism in accordance with the above which includes a convergent chute for funneling the webs of stock material from the roll to a crumpler section on the mechanism, and wherein the axis of rotation of the roll of stock material is so disposed that the peripheral extremity of the mounted roll is substantially no lower or laterally disposed than a longitudinal plane passing through an inner defining surface of the chute at the entrance to the chute.

Another object of the invention is to provide a mechanism of the above described type wherein the transfer vehicle includes means for selectively cutting the dunnage carried thereon into selected lengths at the location of use.

A still further object of the invention is to provide a novel method of producing dunnage and transferring the dunnage direct from the machine producing the same to a transfer vehicle, for subsequent transfer to a desired location of use distant from the dunnage producing area.

Further objects and advantages of the invention will be apparent from the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a somewhat diagrammatic side elevational view of a mechanism embodying the present invention, and including a transfer cart or vehicle.

FIG. 2 is a top plan view of the mechanism of FIG. 1;

FIG. 3 is a generally perspective view of the dunnage producing machine of FIGS. 1 and 2 taken from the rear thereof;

FIG. 3A is a fragmentary 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 portions of the rolled edges of the stock material together for maintaining the pad-like configuration of the dunnage product.

FIG. 3B is a fragmentary view similar to FIG. 3A but illustrating a modified arrangement.

FIG. 4 is a perspective view of the dunnage producing machine of FIGS. 1 and 2 taken generally from the front thereof;

FIG. 5 is a fragmentary detailed view of the crumpler portion of the dunnage producing mechanism, together with power operated gears for 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;

FIG. 6 is a view taken from the opposite side of the mechanism illustrated in FIG. 5;

FIGS. 7 and 8 are respectively front and side elevational views of cutting mechanism utilizable in the dunnage producing machine, for cutting the dunnage product produced on the machine;

FIGS. 9 and 10 are respectively front elevational and top plan views of the chute of the machine;

FIGS. 11 and 12 are perspective views of the transfer vehicle or cart adapted for use in conjunction with the dunnage producing machine, for receiving the pad-like dunnage product from the continuous production on the machine, storing or supporting 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.

FIG. 13 is an enlarged top plan detailed view of pusher mechanism for mounting in the chute of the dunnage producing mechanism of FIGS. 1 and 2;

FIG. 14 is an elevational view of the FIG. 13 structure;

FIG. 15 is a diagrammatic, schematic illustration of a control circuit for the dunnage producing machine;

FIG. 16 is a top plan view of a modified arrangement of dunnage producing machine;

FIG. 17 is a side elevational view of the FIG. 16 machine;

FIG. 18 is an end elevational view taken generally along the plane of line 18--18 of FIG. 17;

FIG. 19 is a fragmentary view of the pad-like dunnage product produced on a dunnage machine utilizing a stock roll of FIG. 3A embodying adhesive means for attaching together confronting portions of the exterior sheet of the stock sheet material.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now again to the drawings, there is illustrated a dunnage producing machine 10 which utilizes a single multi-ply stock roll 12 of sheet-like material such as, for instance, Kraft paper. In the embodiment illustrated, 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 extending through core 14, for rotation of roll 12 relative to the support structure 20, as the paper stock is drawn into the 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 structure 20 while providing for rapid replacement of the stock roll when necessary. In the embodiment illustrated, the three superimposed 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 inches in diameter by approximately 28 to 30 inches in width. However, as will be hereinafter discussed, the diameter of the roll is not particularly important so far as operation of the machine is concerned. What is important is the location of the periphery of the roll as related to the entranceway to the chute of the mechanism, in order to aid in preventing tearing of the sheets of stock as they come off the roll, and as will be hereinafter discussed. One end of the rod 19 extending through the stock roll, is adapted to have an opening therethrough receiving a pin projecting laterally from the rod, for preventing rotation of the rod upon rotation of the roll about rod 19. In other words, the roll of stock frictionally rotates relative to the rod 19 during pulling of the stock material into the dunnage producing mechanism in the embodiment illustrated.

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 (FIGS. 1, 9 and 10) which chute forms a guide and support for the webs of stock material 16, 17 and 18 as they are drawn off the stock roll 12 and are passed to a longitudinally elongated crumpler section 28 of the dunnage producing machine. In the embodiment illustrated, the chute 26 and the crumpler section 28 may be provided as an integral unit which can be conveniently formed of, for instance, fiberglass or plastic or some other such suitable material.

As can be best seen in FIGS. 1, 2 and 9, the chute section 26 comprises a widened mouth or entranceway 30, with the upper, lower and side wall interior surfaces 32, 34, 34a (FIG. 2) of the chute converging rearwardly with respect to one another and with respect to the entranceway. Entranceway 30 is of generally oval configuration (FIG. 9), with the major axis X--X of the oval shape disposed in a generally horizontal plane which passes through the horizontal center plane of the crumpler section 28. The minor axis Y--Y of the oval shaped entranceway is 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 (FIGS. 2, 9 and 10) for providing accessibility to a pusher mechanism 40 (FIGS. 1, 14 and 15) which extends downwardly in depending 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 FIG. 1.

Pusher mechanism 40 in the embodiment illustrated comprises a tubular body portion of generally triangular shape in plan (FIG. 13) and is supported in the chute 26 in relatively 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 provided 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 (FIG. 2) and is secured to the bar 48 as by means of associated nuts 50. A plurality of longitudinally spaced openings may be provided in the bar 48 for selective adjusting of the position of the pusher with respect to the chute 46. It will also be seen that the nuts 50 provide for adjustment for the relative closeness of the body portion of the pusher with respect to the confronting surface 34 of the chute.

As can be seen in FIG. 2, the body portion of the pusher occupies a substantial portion of the crosswise dimension of the bottom wall of the chute, and causes the sheet-like stock material as it passes from the stock roll 12 to the crumpler section 28 to be generally confromed to the chute, thereby causing effective 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 has rounded edges, and as it receives the stock material there beneath, urges it downwardly toward the bottom wall of the chute and aids in preventing tearing of the webs of stock material coming off stock roll 12.

A wheeled counting mechanism 52 may be provided, supported as by means of the aforementioned bar 48, for determining the amount of linear footage of dunnage material produced by the dunnage machine. A top cover 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 of the stock roll 12 is a separating means 54 (FIG. 1). In the embodiment illustrated separating means 54 comprises 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 FIG. 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 separator rod 54c.

The separator mechanism maintains the webs in separated condition prior to their being urged back into generally juxtaposed condition at the pusher mechanism 40, the latter being downstream from the preferably cylindrical separator 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 the stock web 18 therebeneath.

In accordance 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 horizontal plane passing through the aforementioned entranceway bottom 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 (FIG. 10) in its upper and lower walls into which extend connecting or stitching means 58 (FIGS. 5 and 6) for connecting confronting portions of the generally loosely crumpled stock material together as the latter is drawn through the crumpler section by the connecting means. In this connection, the connecting means comprises in the FIGS. 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 rotation relative to the crumpler section 28. Shaft 60 of upper gear 58a is preferably arranged so that the ends of the shaft are mounted in a slotted bracket frame 62 (FIG. 5) with the ends of the shaft being spring loaded as at 64, for urging the shaft downwardly toward the underlying gear 58b. It will be seen, therefore, that the top gear 58a generally floats in its supporting slotted bracket structure 62, with the gear 58a being movable vertically relative to the underlying gear 58b, to thus provide for tension varying of the spacing between the gears as different amounts or thicknesses of material pass therebetween. Such an arrangement aids in preventing tearing of the stock material due to too hard meshing between the connecting gears.

The lower shaft 60a may be rotatably mounted in stationary bearing structure 66 (FIG. 6) and includes a sprocket 67 secured to one end thereof, which in turn is connected by endless chain or 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 the crumpler section 28, they have been rolled substantially inwardly into generally abutting confronting relation 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 portion thereof by the aforementioned meshed gears 58a, 58b.

The webs 16, 17 and 18 are pulled from the periphery of the 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 initially when the stock roll is the heaviest, the periphery of 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 entrance periphery 55. After considerable depletion of the stock roll and therefore considerable lightening thereof the periphery thereof in the embodiment illustrated, will move above a horizontal plane passing through the separating rod 54a.

The aforementioned pushing mechanism 40 urges the webs of 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 material in its movement toward the crumpler section 28.

After passing from the exit opening 74 of the crumpler section 28, the continuously formed pad P (FIG. 4) of stock material 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 (FIG. 7) in which is movably mounted a cutter blade 78a which has a sharpened, preferably replaceable edge 79 adapted for cutting coaction with a stationary cutter edge 78b on the upper cross piece 80 of the cutter frame. Cutter frame 78 includes side leg portions 82, 84, each of which is of hollow construction (FIG. 8) and embodying a guideway or track 82a or 84a (FIG. 8) adapted to receive guide means 86 (in the 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 reciprocal double acting fluid powered motor unit 87 (FIG. 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 FIG. 7. The other end of the motor unit 89 is pivoted as at 90 to a bracket 92 mounted on the support frame for the dunnage machine. Brackets 94 on the cutter frame locate and aid in supporting table surface 96, on which the pad-like dunnage may be supported as it is emitted by the mechanism.

Motor unit 89 is adapted to be controlled in its reciprocal 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 vehicle 102 is provided, for receiving a predetermined amount of dunnage pad from the dunnage machine, winding it into a roll R (FIG. 1) and supporting it on the vehicle for subsequent transfer to an area distant from the dunnage machine 10.

The transfer vehicle 102 comprises a preferably lightweight 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 thereon for initially securing the end of a strip of dunnage pad material thereto, during 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 receive 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. When the roll of dunnage material collected 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 the 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 blade 116 can be utilized to cut the dunnage roll R into the desired lengths at the area to which the cart has been transported to. The transfer cart preferably has diagonally extending hand gripping portions 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 the cart with the cutter mechanism 116 and associated support board 120 thereon 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 (FIG. 1) of the frame portion 106 of the cart.

It will be seen therefore, that with the transfer 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 dunnage 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.

Referring now to FIGS. 16, 17 and 18 there is illustrated another embodiment of the dunnage machine which is of a more compact nature in a horizontal or width direction as compared to the first described embodiment. In this arrangement, the stock roll 12' is mounted for rotation about a vertical axis, with the lower end of the shaft 19' which extends through the hollow core tube 14' of the stock roll, being received in a complementary opening in turntable 230, which is rotatably mounted on bracket structure 20' for rotation about a generally vertical axis, the latter being coincident with the axis of the rod 19'.

The upper end of the rod 19' is received in supported and preferably clamped relation by means of suitable readily releasable clamping means 232, mounted on upper support 20", so that the stock roll 12' can be rapidly mounted on the turntable and clamped by clamping mechanism 232, for rotary movement.

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 the first described embodiment, except that the webs are generally vertically oriented as compared to being generally horizontally oriented as in the first described embodiment.

Divider means 30' comprises vertically oriented rods 54a', 54b', 54c' coacting 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 first described embodiment, except that it is tipped on its side so that the major axis X--X of the oval shaped mouth or entranceway 30' to the chute means 26' is vertically disposed as compared to the horizontal orientation of the first described embodiment.

It will be seen that the separating rod 54c' coacts with the adjacent surface 34' of the chute means in the same general way that the rod 54c coacts with the corresponding surface 34 of the chute of the first described embodiment, and also that the periphery of the stock roll 12' is oriented with respect to a longitudinal plane passing through the surface 34' of the chute means of this embodiment in a similar relationship as in the first described embodiment.

A pusher mechanism 40' may coact with surface 34' in a similar manner as in the first described embodiment, and the webbed stock material from the stock 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 described 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 dunnage material into selected lengths. In most other respects, the FIGS. 16, 17 and 18 embodiment is generally similar to the first described 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 FIGS. 16, 17 and 18 embodiment is that it utilizes much less floor space for a dunnage machine, and while the dunnage product 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.

FIG. 19 discloses another embodiment of dunnage product 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 portions of the inwardly turned or inwardly rolled lateral edges of the stock 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 coupling them together, plain rollers or wheels could be utilized for compressing the confronting portions of the web stock material 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 described 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 the product, and in a similar manner as the product produced by the 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 utilizing adhesive connecting means rather than plain rollers, but with the adhesive strip, it is not necessary to also coin or mechanically stitch the stock material together, to hold it in its pad-like form.

Referring now to FIG. 15, there is shown schematically, a control system for controlling operation of the dunnage mechanism of either the FIGS. 1 and 2 embodiment or the FIGS. 16, 17 and 18 embodiment. The system is adapted for plugging into a conventional 115 volt AC source 237 of power.

A "momentary run" switch 238 (FIGS. 1, 2 and 13) is provided for momentarily actuating the drive motor 70 of the mechanism so long as the switch is held in compressed condition, for producing a selected amount of cushioning dunnage. Switch 238 is spring loaded and when actuated, the normally open contact thereof closes and the normally closed contact thereof opens, whereby the electric motor 70 is energized from 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 actuating button 240a for the 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 normally open contact opens, and the normally closed contact is once again closed.

Also located on table surface 96 on opposite sides of the exit mouth 74 of the dunnage machine is a auxiliary left, cutter actuating switch 244, and a auxiliary right hand cutter actuating switch 246, which are arranged in series with a master 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 FIGS. 1 and 2.

Either the left hand auxiliary switch 244 or the right hand auxiliary switch 246 must be actuated in conjunction with the master switch 248 in order that energization of the fluid actuated motor unit 89 actuating the cutter mechanism 76, can occur. It will be seen upon actuation of master switch 248, the normally open contact is closed and upon actuation of 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 (FIG. 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 closes, thereby de-energizing 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 78a 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 mechanism, upon actuation thereof.

A cover interlock switch 254 (FIG. 13) is also preferably provided in the control system to disable the electric power to the machine from the 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 relatively low density pad-like cushioning dunnage, and wherein the dunnage can be rapidly and effectively 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 subsequent transfer to areas remote from the dunnage machine. The invention also provides a novel method for producing and handling the dunnage material, greatly facilitating the production of dunnage from a single dunnage machine, as well as providing 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 thereof, but it is recognized that various modifications are possible within the scope of the invention claimed.

Claims

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 material 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 the roll toward said crumpler means, chute means for causing inward rolling of the lateral 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 separating means for 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 the roll through said separating means and into said crumpler means, said mounting means being so disposed that the peripheral extremity of the stock roll will not extend substantially beyond a longitudinal plane passing through a certain inner defining surface of said chute means at said entrance mouth, and 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.

2. A mechanism in accordance with claim 1 including cutter means disposed downstream of said crumpler means for cutting the dunnage product into selective lengths.

3. A mechanism 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.

4. A mechanism in accordance with claim 1 wherein said chute means and said crumpler means are integrally molded as a unit.

5. A mechanism in accordance with claim 4 wherein said integral chute means and crumpler means are formed of fiberglass resin.

6. A mechanism in accordance with claim 3 wherein said entrance mouth of said chute means is of generally oval configuration 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 longitudinal axis of said crumpler means, said separating means comprising 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.

7. A mechanism in accordance with claim 1 wherein said pusher means comprises a generally triangular shaped member extending 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 movable sheets of stock material between said pusher means and said surface.

8. A mechanism in accordance with claim 1 wherein said sidewalls of said chute means are of arcuate interiorly concave configuration in cross section and merge smoothly with said upper and lower walls.

9. A mechanism in accordance with claim 1 wherein said separating means comprises a plurality of generally vertically spaced bars extending transverse of said support and about which a respective sheet of the stock material moves in its travel 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, and wherein the material of said stock roll is withdrawn from the underside of said roll into said separating means.

10. In a method of producing low density cushioning dunnage from sheet-like stock material comprising pulling from a rotatable composite multi-ply roll of stock material the webs of sheet-like material, separating the webs and then generally reimposing the webs together while rolling the lateral edges of the webs inwardly utilizing a lengthwise extending convergent chute having an entranceway, crumpling the rolled edge webs of material inwardly into a pad-like configuration of relatively low density per unit volume so that the rolled edges of the sheet-like material are disposed in generally confronting abutting condition, then connecting the rolled and crumpled edge portions together along the juncture thereof to form a unitary pad-like dunnage product, and wherein the pulling of the webs from the periphery of the rotatable roll and the separating of the webs into individual webs and the reimposing of the webs together while rolling the lateral edges of the webs inwardly is accomplished in a zone defined in general between substantially parallel longitudinal planes passing through respectively the axis of rotation of the roll and a predetermined surface of said chute at said entranceway, and wherein the material from said roll is withdrawn therefrom in the general lengthwise direction of extension of said chute, and wherein said connecting the rolled and crumpled edge portions together is accomplished by pressure applying means in conjunction with adhesive means for maintaining the unitary pad-like dunnage product and wherein the pressure applying means acts generally centrally of the product in a direction lengthwise thereof.

11. 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 material 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 the roll toward said crumpler means, chute means for causing inward rolling of the lateral edges of the sheet-like material into generally rolled form prior to entry of the sheet-like stock material into including 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 separating means for funneling rolled edge stock material toward said crumpler means, means for connecting the 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 the roll through said separating means and into said crumpler means, and said mounting means being so disposed that the peripheral extremity of the stock roll will not extend substantially beyond a longitudinal plane passing through a certain inner defining surface of said chute means at said entrance mouth, and wherein said connecting means comprises generally vertically spaced rotatable meshed gear means disposed generally centrally of said crumpler means in a direction transverse of the latter and adapted to stitch confronting rolled edges of the sheet-like material together as the latter passes through said crumpler means, and means movably mounting one of said gear means with respect to the other of said gear means for providing for movement of the gear means relative to one another during the stitching operation.

12. A mechanism in accordance with claim 11 wherein said movably mounting means includes resilient means urging one of said gear means toward the other of said gear means, and means permitting movement of one of said gear means relative to the other of said gear means.

13. A mechanism in accordance with claim 11 wherein said entrance mouth is of generally oval shape in end elevation with the major axis of said entry opening being disposed in a substantially horizontal plane, the last mentioned plane passing through the mesh area of said gear means.

14. A cushioning mechanism for producing 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 elongated roll of sheet-like stock material, crumpler means on said support adapted to receive the sheet-like stock material therein, means for separating the sheets of stock material as the latter move from the roll toward said crumpler means, chute means for causing inward rolling of the lateral edges of the sheet-like material into generally rolled form prior to entry of the sheet-like material into said crumpler means, said chute means being adapted to funnel 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 mounting means being arranged for vertical mounting of the stock roll for providing a relatively narrow width mechanism, and wherein said mounting means comprises a rotatable table.

15. A mechanism in accordance with claim 14 wherein said chute means includes an entrance mouth disposed in confronting relation to said separating means, and wherein said mounting means is so positioned that the peripheral extremity of the vertically mounted stock roll will be so disposed so as not to extend laterally substantially beyond a longitudinal plane passing through a certain inner defining surface of said chute means at said entrance mouth.

16. 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 material 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 lateral 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 separating 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 passing 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 extension 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.

17. The combination in accordance with claim 16 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.

18. 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 material 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 the roll toward said crumpler means, chute means for causing inward rolling of the lateral 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 separating means for 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 the roll through said separating means and into said crumpler means, and said mounting means being so disposed that the peripheral extremity of the stock roll will not extend substantially beyond a longitudinal plane passing through a certain inner defining surface of said chute means at said entrance mouth, cutter means disposed downstream of said crumpler means for cutting dunnage product into lengths, and wherein said cutter means comprises a frame having guideway means therein, and a movable cutter blade having means thereon received in said guideway means for guiding 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 predetermined lengths upon predetermined actuation of associated reciprocable power means.