Dunnage conversion machine and method with assisted tear apparatus

A dunnage conversion machine includes a forming assembly configured to form a sheet stock material into a strip of dunnage, and a feeding assembly downstream of the forming assembly that is configured to pull the sheet stock material through the forming assembly. The machine also includes a tear assist assembly downstream of the feeding assembly that includes a pinch arm on one side of the path and a stop opposing the pinch arm on an opposite side of the path. The pinch arm is movable between a resting position in which the pinch arm is located on the one side of the path, and a pinching position in which the pinch arm is located in the path to capture the strip of dunnage between the pinch arm and the stop. Reversing the feed assembly while the pinch arm is in the pinching position causes the strip of dunnage to tear.

FIELD OF THE INVENTION

The present invention relates generally to the field of dunnage conversion systems, and more particularly to a dunnage conversion machine and method with means for separating a formed dunnage product.

BACKGROUND

In the process of packing an article in a packaging container before shipping the article from one location to another, a protective packaging material (dunnage product) is typically placed in the packaging container with the article. The dunnage product is included to fill any voids or to cushion the article during the shipping process. Paper packing material is an ecologically-friendly packing material that is recyclable, biodegradable, and composed of a renewable resource. While paper in sheet form could possibly be used as a protective packaging material, it may be preferable to convert the sheets of paper to a lower-density dunnage product.

Once converted in a dunnage conversion machine, a discrete dunnage product typically is separated from the dunnage conversion machine by a manual pulling process or by a semi-automatic or automatic bladed cutting mechanism in the dunnage conversion machine. Manual tearing becomes difficult when the formed dunnage product includes multiple layers of sheet material connected together. Additionally, manual tearing is difficult when there is no perforation provided in the area that needs to be separated. Semi-automatic and automatic bladed cutting mechanisms typically are large, heavy, and expensive to incorporate into dunnage conversion machines.

SUMMARY

We provide a dunnage conversion machine and method that uses a tear assist assembly to improve on both manual tearing processes and semi-automatic or automatic bladed cutting devices previously used to separate discrete dunnage products from dunnage conversion machines. The dunnage conversion machine according to the present invention includes a forming assembly for forming sheet stock material into a strip of dunnage, a feeding assembly for pulling the sheet stock material from a supply and through the forming assembly, and a tear assist assembly for cooperating with the feeding assembly to create a tear in at least a portion of the strip of dunnage. The tear assist assembly, therefore, assists in the separation of a discrete dunnage product from the strip of dunnage for withdrawal from the dunnage conversion machine without a cutting blade.

Specifically, an exemplary dunnage conversion machine includes a forming assembly that is configured to form a sheet stock material into a strip of dunnage having a lower density than the sheet stock material. The dunnage conversion machine also includes a feeding assembly downstream of the forming assembly that is configured to pull the sheet stock material from a supply, through the forming assembly, and to advance the strip of dunnage along a path in a downstream direction. The dunnage conversion machine also includes a tear assist assembly downstream of the feeding assembly. The tear assist assembly includes a pinch arm on one side of the path and a stop opposing the pinch arm on an opposite side of the path from the pinch arm. The pinch arm is movable between a resting position in which the pinch arm is located on the one side of and out of the path, and a pinching position in which the pinch arm is located in the path to capture the strip of dunnage between the pinch arm and the stop. The dunnage conversion machine also includes a controller configured to control operation of the dunnage conversion machine.

The controller may be configured to operate the feeding assembly in a feeding direction to advance a desired length of the strip of dunnage in the downstream direction and stop the operation of the feeding assembly in the feeding direction after the desired length of the strip of dunnage has been advanced. The controller also may be configured to activate the tear assist assembly to move the pinch arm from the resting position to the pinching position to capture the strip of dunnage between the pinch arm and the stop at a capture point on the strip of dunnage. The controller also may then be configured to operate the feeding assembly in a reverse direction, opposite the feeding direction, to reverse an upstream region of the strip of dunnage upstream of the capture point in an upstream direction to create a tear in the strip of dunnage. The controller then may be configured to stop the operation of the feeding assembly in the reverse direction and deactivate the tear assist assembly to move the pinch arm from the pinching position to the resting position to release the strip of dunnage between the pinch arm and the stop.

The feeding assembly may include a pair of rotating members that cooperate to advance and reverse the strip of dunnage along the path.

The controller may be configured to operate the feeding assembly in a feeding direction for a first predetermined number of rotations of the pair of rotating members to advance a desired length of the strip of dunnage. The controller therefore may also be configured to stop the operation of the feeding assembly in the feeding direction after the pair of rotating members have rotated the first predetermined number of rotations.

The controller may be configured to operate the feeding assembly in a reverse direction for a second predetermined number of rotations of the pair of rotating members to reverse an upstream region of the strip of dunnage upstream of the capture point in an upstream direction to create a tear in the strip of dunnage. The controller therefore may also be configured to stop the operation of the feeding assembly in the reverse direction after the pair of rotating members have rotated the second predetermined number of rotations.

The controller may be configured to operate the feeding assembly in the feeding direction for a first predetermined period of time to advance the desired length of the strip of dunnage. The controller therefore may also be configured to stop the operation of the feeding assembly in the feeding direction after the first predetermined period of time has passed.

The controller may be configured to operate the feeding assembly in the reverse direction for a second predetermined period of time to reverse the upstream region of the strip of dunnage in the upstream direction and create a tear in the strip of dunnage. The controller therefore may also be configured to stop the operation of the feeding assembly in the reverse direction after the second predetermined period of time has passed.

The dunnage conversion machine may additionally include a dunnage production sensor configured to detect a length of the strip of dunnage that has been advanced in the downstream direction.

The tear assist assembly may include a motive device operatively coupled to the pinch arm and configured to move the pinch arm between the resting position and the pinching position.

The controller may be configured to activate the tear assist assembly to move the pinch arm from the resting position to the pinching position by sending a capture signal to the motive device after stopping the operation of the feeding assembly in the feeding direction. The controller also may be configured to deactivate the tear assist assembly to move the pinch arm from the pinching position to the resting position by sending a release signal to the motive device after stopping the operation of the feeding assembly in the reverse direction.

The motive device may include an electric motor.

The feeding assembly may be configured to connect two or more plies of the strip of dunnage advancing therebetween to form a connected portion of the strip of dunnage.

The tear assist assembly may be configured to capture at least the connected portion of the strip of dunnage such that the tear is created at least in the connected portion of the strip of dunnage.

An exemplary method for making a discrete dunnage product in a dunnage conversion machine may include a step of forming a sheet stock material into a strip of dunnage having a lower density than the sheet stock material and a step of advancing a desired length of the strip of dunnage in a downstream direction along a path of the dunnage conversion machine. The method may include a step of capturing the strip of dunnage at a capture point. The method may then include a step of reversing an upstream region of the strip of dunnage in an upstream direction, opposite the downstream direction, to create a tear in the upstream region of the strip of dunnage to at least partially separate the discrete dunnage product from the strip of dunnage. The upstream region is upstream of the capture point. The method then includes a step of releasing the strip of dunnage at the capture point. The dunnage conversion machine includes a tear assist assembly including a pinch arm on one side of the path and a stop opposing the pinch arm on an opposite side of the path from the pinch arm. The steps of capturing and releasing therefore include moving the pinch arm between a resting position in which the pinch arm is located on the one side of the path, and a pinching position in which the pinch arm is located in the path.

The step of advancing may include rotating a pair of rotating members in a feeding direction for a first predetermined number of rotations. The pair of rotating members rotating in the feeding direction cooperate to advance the strip of dunnage in the downstream direction.

The step of reversing may include rotating a pair of rotating members in a reverse direction for a second predetermined number of rotations. The pair of rotating members rotating in the reverse direction cooperate to reverse the strip of dunnage in the upstream direction.

The step of advancing may occur for a first predetermined period of time.

The step of reversing may occur for a second predetermined period of time.

The step of capturing may include activating the tear assist assembly to move the pinch arm from the resting position to the pinching position to capture the strip of dunnage between the pinch arm and the stop at the capture point.

The step of releasing may include deactivating the tear assist assembly to move the pinch arm from the pinching position to the resting position.

DETAILED DESCRIPTION

We will now describe in detail a dunnage conversion machine and method that uses a tear assist assembly to improve on both manual tearing processes and semi-automatic or automatic bladed cutting devices previously used to separate discrete dunnage products. The tear assist assembly cooperates with a feeding assembly in the dunnage conversion machine to create a tear in at least a portion of a strip of dunnage formed in the dunnage conversion machine, without the use of a bladed cutting device. Our tear assist assembly, therefore, allows for easy manual separation and withdrawal of a discrete dunnage product from the dunnage conversion machine.

FIG.1shows a schematic dunnage conversion machine10with a forming assembly12and a feeding assembly14that cooperate to draw a sheet stock material22from a supply20of sheet stock material and to convert the sheet stock material22into a strip of dunnage24as it travels through the dunnage conversion machine10in a downstream direction30. The dunnage conversion machine10additionally includes a tear assist assembly16, downstream of the feeding assembly14, that is configured to assist in separating a discrete dunnage product28from the substantially continuous strip of dunnage24formed by the dunnage conversion machine10without a cutting blade. The dunnage conversion machine10includes a controller32for controlling the operation of the dunnage conversion machine10.

The supply20of sheet stock material22may include, for example, one or more plies of sheet stock material22supplied as a roll or a fan-folded stack. Multiple rolls or stacks may be used to provide multiple plies of sheet stock material22for conversion. Paper is an environmentally responsible choice for the sheet stock material22because paper generally is recyclable, reusable, and composed of a renewable resource. Therefore, an exemplary sheet stock material22for use in the dunnage conversion machine10includes either a single ply or a multi-ply kraft paper provided in either roll form or a series of connected rectangular pages in a fan-folded stack. Subsequent rolls or stacks may be spliced to trailing ends of preceding rolls or stacks to provide a continuous length of sheet stock material22to the dunnage conversion machine10.

The forming assembly12, through which the sheet stock material22is pulled in the downstream direction30, is configured to convert the relatively planar sheet stock material22into a strip of dunnage24that has a three-dimensional shape with a smaller width dimension, a larger thickness dimension, and a lower density than the sheet stock material22. For example, the forming assembly12may be configured to shape and randomly crumple at least a portion of the sheet stock material22. The forming assembly12may include a converging shaping chute and a forming member, such as a forming frame, that extends into the converging shaping chute for shaping the relatively planar sheet stock material22into the strip of dunnage24. Specifically, the relatively planar sheet stock material22may be fed into the forming member between the converging shaping chute and the forming member such that side edges of the sheet stock material22are turned inwardly towards one another around the forming frame. When turned inwardly, the sheet stock material22may randomly crumple and the side edges of the sheet stock material22may come together such that multiple layers overlap each other. The forming assembly is not limited to the described forming assembly12, however, but may be of any other type suitable for forming the relatively planar sheet stock material22into the strip of dunnage24having a three-dimensional shape with lower density than the sheet stock material22.

The feeding assembly14is located downstream of the forming assembly12in the dunnage conversion machine10and is configured to perform at least one, and generally two functions in the operation of the dunnage conversion machine10. One function is a feeding function. To perform the feeding function, the feeding assembly14is configured to pull the sheet stock material22from the supply20and through the forming assembly12, pulling the strip of dunnage24from the forming assembly12. In doing so, the feeding assembly14is also configured to feed the continuous sheet stock material22from the supply20of sheet stock material through the forming assembly12in the downstream direction30.

Another function of the feeding assembly14may be a connecting function. To perform the connecting function, the feeding assembly14may be configured to connect together at least a portion of overlapping layers of the two or more plies, such as the overlapping side edges, in the strip of dunnage24drawn from the forming assembly12to form a connected strip of dunnage24downstream of the feeding assembly14. The portion of the strip of dunnage24in which the two or more plies, or the overlapping layers, are connected is referred to herein as a connected portion of the connected strip of dunnage24.

The feeding assembly14is configured to advance the strip of dunnage24along the path46of the dunnage conversion machine10to the tear assist assembly16located downstream of the feeding assembly14. The tear assist assembly16is configured to cooperate with the feeding assembly14to at least partially tear, or otherwise separate, at least a portion of the strip of dunnage24to assist in separating a discrete dunnage product28of a desired length from the substantially continuous strip of dunnage24. Specifically, the tear assist assembly16is configured to capture the strip of dunnage24at a capture point on the strip of dunnage24. Once the strip of dunnage24is captured, the feeding assembly14operates in reverse to at least partially tear, or otherwise separate, at least a portion of the strip of dunnage24upstream of the capture point. The capture point may be at least in the connected portion of the connected strip of dunnage24such that the tear is created at least in the connected portion of the connected strip of dunnage24.

The controller32is configured to control the operation of the dunnage conversion machine10and each of its component parts. The controller32may include a processor, a memory, and a program stored in the memory. The controller32may additionally include one or more input devices, such as for determining the desired length of the strip of dunnage24, and one or more outputs, including outputs for controlling elements of the dunnage conversion machine10. The input devices can be connected to or include one or more of a keyboard, a mouse, a touch screen display, a scanner or sensor, a bar code reader, a radio frequency identification device (RFID) sensor, a microphone, a camera, etc. The controller32can be programmed to recognize the appropriate inputs that represent a desired length of the strip of dunnage24, or identify a location to look up one or multiple lengths needed for a particular packing container.

With reference toFIGS.2and3, an exemplary feeding assembly14and an exemplary tear assist assembly16will now be described in more detail. Whether the feeding assembly14has one or both of the feeding function and the connecting function, the exemplary feeding assembly14includes a pair of rotating members40. The pair of rotating members40include a first rotating member42and a second rotating member44which are spaced across a path46of the dunnage conversion machine10by which the strip of dunnage24travels. The pair of rotating members cooperate to advance the strip of dunnage24down the path46in the downstream direction30. To perform the feeding function, the pair of rotating members40progressively engage the strip of dunnage24on opposite transverse sides thereof to pull the strip of dunnage24through the forming assembly12and, in turn, pull the sheet stock material22from the supply of sheet stock material20and into the forming assembly12. The first rotating member42and the second rotating member44each have a surface that provides sufficient friction to grip the strip of dunnage24, and may be knurled or have a rubber or other high-friction surface, for example, to provide the desired grip on the sheet stock material22. The first rotating member42and the second rotating member44preferably, but not necessarily, are biased against one another to maintain a grip on the strip of dunnage24passing therebetween.

To perform the connecting function, the pair of rotating members40may be configured to deform the strip of dunnage24on opposite sides thereof to form the connected portion of the connected strip of dunnage24. Specifically, the first rotating member42and the second rotating member44alternatively may be formed by a pair of intermeshing gears that crimp the layers of sheet stock material22passing therebetween, or may cut the sheet stock material22to form one or more tabs displaced from the plane of adjacent portions of the sheet stock material22to hold the connected strip of dunnage in its three-dimensional shape. For example, the first rotating member42and the second rotating member44may each have interlaced teeth for deforming the strip of dunnage24passing therebetween. By deforming the strip of dunnage24, the interlaced teeth thereby mechanically interlock the plies or overlapping layers of sheet stock material22in the strip of dunnage24along lines of connection to hold them together in the connected strip of dunnage24. This mechanical connection is distinguished from a chemical or adhesive bond between the plies or overlapping layers. The first rotating member42and the second rotating member44may be configured to additionally flatten, crease, emboss, cut, or punch or otherwise deform the sheet stock material22as it passes therebetween.

The tear assist assembly16includes a pinch arm48on one side of the path46and a stop50on an opposite side of the path46. The stop50opposes the pinch arm48and provides a surface against which the inch arm48can capture the strip of dunnage24. The stop50may include a plate or another pinch arm positioned on the opposite side of the path46from the pinch arm48. The stop50may be formed as a part of a chute that defines the path46from an inlet adjacent the feeding assembly to an outlet downstream of the tear assist assembly.

The pinch am48is moveable between a resting position (FIG.2) and a pinching position (FIG.3). In the resting position (FIG.2), the pinch arm48is located on the one side of the path46opposite and apart from the stop50and out of the path46so as not to impede the progress of the strip of dunnage passing thereby. Therefore, in the resting position of the pinch arm48(FIG.2), the strip of dunnage24is able to freely pass between the pinch arm48and the stop50as it is advanced along the path46in the downstream direction30by the feeding assembly14. In the pinching position (FIG.3), the pinch arm48is located in the path46to capture the strip of dunnage24passing therethrough between the pinch arm48and the stop50. Therefore, in the pinching position (FIG.3), the strip of dunnage24can no longer freely pass between the pinch arm48and the stop50, as it is captured and held therebetween at the capture point.

If the strip of dunnage24includes a line of connection, in which multiple layers of sheet stock material22are connected, the pinch arm48and the stop50preferably are positioned to engage the strip of dunnage24at the line of connection. If the strip of dunnage24includes multiple lines of connection, the tear assist assembly16may include multiple pinch arm48and stop50pairs positioned to engage respective lines of connection.

The pinch arm48may be pivotably or rotatably mounted in the dunnage conversion machine10such that the pinch arm48pivots or rotates between the resting position and the pinching position. Alternatively, the pinch arm48may be mounted in the dunnage conversion machine10such that the pinch arm48moves linearly between the resting position and the pinching position. Movement of the pinch arm48is powered by a motive device in at least one direction of motion. The pinch arm48may be biased to the resting position with a spring and may be actively moved to the pinching position by a motive device58, the operation of which will be described more fully below with reference toFIG.8.

With reference toFIGS.4to7, the cooperation of the feeding assembly14and the tear assist assembly16to at least partially tear, or otherwise separate, at least a portion of the strip of dunnage24will now be described. As depicted inFIG.4, the controller32generally is configured to operate the feeding assembly14in a feeding direction52to advance the desired length of the strip of dunnage24along the path46in the downstream direction30. The dunnage conversion machine10may include a dunnage production sensor34for detecting a length of the strip of dunnage24that has been advanced. The dunnage production sensor34is coupled to the controller32and may be separate or integrated into the controller32. Once the desired length of the strip of dunnage24has been advanced, the controller32is configured to stop the operation of the feeding assembly14in the feeding direction52.

The controller32may be configured to operate the feeding assembly14in the feeding direction52for a first predetermined period of time. In this embodiment, the dunnage conversion machine10includes a timer38for determining a period of time that has passed. The timer38is coupled to the controller32and may be separate or integrated into the controller32. The first predetermined period of time, for example, may be chosen to be sufficient for advancing the desired length of the strip of dunnage24. After the first predetermined period of time has passed, the controller32is configured to stop the operation of the feeding assembly14in the feeding direction52.

Alternatively, the controller32may be configured to operate the feeding assembly14in the feeding direction52for a first predetermined number of rotations of the pair of rotating members40. In this embodiment, the dunnage conversion machine10may include a rotation counter31for determining the number of rotations that the pair of rotating members40have rotated. The rotating counter31is coupled to the controller32and may be separate or integrated into the controller32. The first predetermined number of rotations, for example, may be chosen to be sufficient for advancing the desired length of the strip of dunnage24. After the pair of rotating members40have rotated the first predetermined number of rotations, the controller32is configured to stop the operation of the feeding assembly14in the feeding direction52.

As depicted inFIG.5after the desired length of the strip of dunnage24has been advanced, the controller32is configured to stop the operation of the feeding assembly14in the feeding direction52, as previously described. The conversion machine32is then configured to activate the tear assist assembly16to move the pinch arm48from the resting position (FIGS.2and4) to the pinching position (FIGS.3and5) to capture the strip of dunnage24between the pinch arm48and the stop at the capture point54.

Moving on toFIG.6, once the tear assist assembly16has been activated to capture the strip of dunnage24between the pinch arm48and the stop50, the controller32is configured to operate the feeding assembly14in a reverse direction53, opposite the feeding direction52. The dunnage conversion machine10may include a pinch arm activation sensor51for detecting that the pinch arm48is in the pinching position. When the pinch arm activation sensor51detects that the pinch arm48is in the pinching position, the controller32directs the feeding assembly14to operate in the reverse direction53. In this way, the controller32is configured to operate the feeding assembly14in the reverse direction53only when the pinch arm48is in the pinching position.

The controller32is configured to operate the feeding assembly14in the reverse direction53to at least partially tear, or otherwise separate, at least a portion of the strip of dunnage24. For example, the feeding assembly14, operating in the reverse direction53while the strip of dunnage24is captured between the pinch arm48and the stop50at the capture point54, pulls an upstream portion of the strip of dunnage24(i.e., a portion of the strip of dunnage24upstream of the capture point54) in the upstream direction31, opposite the downstream direction30. This causes a tear56to be created in the strip of dunnage24in the upstream portion of the strip of dunnage24. In the embodiment in which the strip of dunnage24includes a connected portion, the capture point54preferably is at least in the connected portion such that the tear56is created at least in the connected portion, where manually completing separation of a dunnage product from the strip of dunnage24may be more difficult. The tear56is at least a partial tear.

The controller32may be configured to operate the feeding assembly14in the reverse direction53for a second predetermined period of time using the timer38. The second predetermined period of time may be chosen to be sufficient for reversing the strip of dunnage24enough to create the tear56in the strip of dunnage24. After the second predetermined period of time has passed, the controller32is configured to stop the operation of the feeding assembly14in the reverse direction53.

Alternatively, the controller32may be configured to operate the feeding assembly14in the reverse direction53for a second predetermined number of rotations of the pair of rotating members40. The second predetermined number of rotations, for example, may be chosen to be sufficient for reversing the strip of dunnage24enough to create the tear56in the strip of dunnage24. After the pair of rotating members have rotated the second predetermined number of rotations, the controller32is configured to stop the operation of the feeding assembly14in the reverse direction53.

As depicted inFIG.7, after the tear56has been created, the controller32is configured to stop the operation of the feeding assembly14in the reverse direction53, as previously described. The conversion machine32is then configured to deactivate the tear assist assembly16to move the pinch arm48from the pinching position (FIGS.3,5and6) to the resting position (FIGS.2,4, and7) to release the strip of dunnage24between the pinch arm48and the stop50.

With reference toFIG.8, at least one direction of movement of the pinch arm48between the resting position (FIGS.2,4, and7) and the pinching position (FIGS.3,5, and6) is driven by a motive device58. The motive device58may include a low-torque, high speed electric motor, pneumatic motor, hydraulic motor, solenoid, or any other device that can move the pinch arm48relative to the stop50. The motive device58can move the pinch arm48in both directions, or a spring or other biasing device may be used to move the pinch arm48in one direction. The motive device58is operatively coupled to the controller32and the pinch arm48and is configured to move the pinch arm48between the resting position (FIGS.2,4, and7) and the pinching position (FIGS.3,5, and6). The controller32is configured to activate the tear assist assembly16to move the pinch arm48from the resting position (FIGS.2,4, and7) to the pinching position (FIGS.3,5, and6) after stopping the operation of the feeding assembly14in the feeding direction52. The controller32is configured to deactivate the tear assist assembly16to move the pinch arm48from the pinching position (FIGS.3,5, and6) to the resting position (FIGS.2,4, and7) after stopping the operation of the feeding assembly14in the reverse direction53.

We will now describe a method for making a discrete dunnage product in a dunnage conversion machine, such as with the dunnage conversion machine10and its various components, as previously described herein. The method includes a step of forming a sheet stock material into a strip of dunnage having a lower density than the sheet stock material. The method includes a step of advancing a desired length of the strip of dunnage in a downstream direction along a path of the dunnage conversion machine. The advancing step may stop after the desired length of the strip of dunnage has been advanced.

The method may additionally include a step of detecting that the desired length of the strip of dunnage has been advanced. The advancing step may be stopped after the step of detecting that the desired length of the strip of dunnage has been advanced.

The advancing step may occur for a first predetermined period of time. Accordingly, the method may additionally include a step of detecting that the first predetermined period of time has passed. The step of advancing may then be stopped after the detecting that the first predetermined period of time has passed.

The advancing step may include rotating a pair of rotating members, such as those previously described with reference toFIGS.2and3, in a feeding direction for a first predetermined number of rotations. The pair of rotating members rotating in the feeding direction cooperate to advance the strip of dunnage in the downstream direction. Accordingly, the method may additionally include a step of detecting that the pair of rotating members have rotated in the feeding direction for the first predetermined number of rotations. The advancing step may then be stopped after the detecting that the pair of rotating members have rotated in the feeding direction for the first predetermined number of rotations. The advancing step also may include connecting multiple layers, specifically connecting multiple layers with the rotating members in a connecting portion of the strip of dunnage.

The method additionally includes step of capturing the desired length of the strip of dunnage at a capture point. As previously described, the dunnage conversion machine10includes a tear assist assembly16(FIG.3) that includes a pinch arm on one side of the path and a stop opposing the pinch arm on an opposite side of the path from the pinch arm. The step of capturing, therefore, may include a step of activating the tear assist assembly to move the pinch arm from a resting position to a pinching position. As previously described, in the resting position the pinch arm is located on the one side of the path, and in the pinching position the pinch arm is located in the path to capture the desired length of the strip of dunnage between the pinch arm and the stop at the capture point. In one embodiment, the capturing step includes engaging the connecting portion, and perhaps only the connecting portion, to initiate a tear in the connecting portion.

The method then includes a step of reversing an upstream region of the desired length of the strip of dunnage in an upstream direction, opposite the downstream direction after the capturing step. The upstream region of the desired length of the strip of dunnage is upstream of the capture point. The step of reversing creates a tear in the strip of dunnage to at least partially separate the discrete dunnage product from the desired length of the strip of dunnage.

The step of reversing may occur for a second predetermined period of time. Accordingly, the method includes stopping the reversing step after the second predetermined period of time has passed.

Alternatively, the reversing step may include rotating the pair of rotating members in a reverse direction for a second predetermined number of rotations. The pair of rotating members rotating in the reverse direction cooperate to reverse the strip of dunnage in the upstream direction. Accordingly, the method may additionally include a step of detecting that the pair of rotating members have rotated in the reverse direction for the second predetermined number of rotations. The step of reversing may then be stopped after the detecting the second predetermined number of rotations in the reverse direction.

The method also includes a step of releasing the desired length of the strip of dunnage at the capture point after the reversing step. The step of releasing may include a step of deactivating the tear assist assembly to move the pinch arm from the pinching position to the resting position. The method may additionally include a step of separating the discrete dunnage product from the desired length of the strip of dunnage. And the advancing step may be a first advancing step, and the method may further include a second advancing step after the step or releasing the desired length of the strip of dunnage after the reversing step. If the reversing step does not completely separate a discrete dunnage product from the strip of dunnage, the user can manually separate a discrete dunnage product from the strip of dunnage after the reversing step.

The dunnage conversion machine and method of operating the dunnage conversion machine thus includes a tear assist assembly for creating a tear in at least a portion of a strip of dunnage passing therethrough without employing a cutting blade. The tear assist assembly improves on manual tearing processes and bladed cutting devices previously employed in conventional dunnage conversion machines to separate discrete dunnage products therefrom. With the dunnage conversion machine including the tear assist assembly, a strip of dunnage may be formed from a supply of sheet stock material and a discrete dunnage product may be separated from the strip of dunnage without the added expense of a cutting blade. If the strip of dunnage is only partially torn, preferably torn at least in the line of connection, if any, a discrete dunnage product may be easily separated from the strip of dunnage manually.

In summary, an exemplary dunnage conversion machine10includes a forming assembly12that is configured to form a sheet stock material22into a strip of dunnage24having a lower density than the sheet stock material22. The dunnage conversion machine10also includes a feeding assembly14downstream of the forming assembly12that is configured to pull the sheet stock material22from a supply20, through the forming assembly12, and to advance the strip of dunnage24along a path46in a downstream direction30. The dunnage conversion machine10also includes a tear assist assembly16downstream of the feeding assembly14. The tear assist assembly16includes a pinch arm48on one side of the path46and a stop50opposing the pinch arm48on an opposite side of the path46from the pinch arm48. The pinch arm48is movable between a resting position in which the pinch arm48is located on the one side of and out of the path46, and a pinching position in which the pinch arm48is located in the path46to capture the strip of dunnage24between the pinch arm48and the stop50. The dunnage conversion machine10also includes a controller32configured to control operation of the dunnage conversion machine10. Reversing the feed assembly14while the pinch arm48is in the pinching position causes the strip of dunnage24to tear.

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