Abstract:
A cushioning conversion machine and related methodology characterized by one or more features including, inter alia, a feeding/connecting assembly which enables an operator to easily vary a characteristic, for example the density, of the cushioning product; a feeding/connecting assembly wherein input and/or output wheels or rollers thereof are made at least in part of an elastomeric or other friction enhancing material, which reduces the cost and complexity of the input and output rollers; a manual reversing mechanism that is useful, for example, for clearing paper jams; a modular arrangement of a forming assembly and feeding/connecting assembly in separate units that may be positioned remotely from one another, as may be desired for more efficient utilization of floor space; a turner bar which enables alternative positioning a stock supply roll; and a volume expanding arrangement cooperative with the feeding/connecting assembly for reducing the density of the cushioning product and increasing product yield.

Description:
RELATED APPLICATION DATA  
       [0001]     This is a continuation of U.S. patent application Ser. No. 10/921,701 filed Aug. 19, 2004, which is a divisional of U.S. Pat. No. 6,783,489 filed on Sep. 2, 1999, which is a continuation of U.S. Pat. No. 6,019,715 filed Apr. 13, 1998, which is a continuation of International Application No. PCT/US96/10899, filed Jun. 26, 1996, which is a continuation-in-part of U.S. Provisional Patent Application No. 60/000,496 filed Jun. 26, 1995, all of which are hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The herein described invention relates generally to a cushioning conversion machine and method for converting sheet-like stock material into a cushioning product.  
       BACKGROUND OF THE INVENTION  
       [0003]     In the process of shipping an item from one location to another, a protective packaging material is typically placed in the shipping case, or box, to fill any voids and/or to cushion the item during the shipping process. Some conventional protective packaging materials are plastic foam peanuts and plastic bubble pack. While these conventional plastic materials seem to adequately perform as cushioning products, they are not without disadvantages. Perhaps the most serious drawback of plastic bubble wrap and/or plastic foam peanuts is their effect on our environment. Quite simply, these plastic packaging materials are not biodegradable and thus they cannot avoid further multiplying our planet&#39;s already critical waste disposal problems. The non-biodegradability of these packaging materials has become increasingly important in light of many industries adopting more progressive policies in terms of environmental responsibility.  
         [0004]     The foregoing and other disadvantages of conventional plastic packaging materials have made paper protective packaging material a very popular alterative. Paper is biodegradable, recyclable and composed of a renewable resource, making it an environmentally responsible choice for conscientious industries.  
         [0005]     While paper in sheet form could possibly be used as a protective packaging material, it is usually preferable to convert the sheets of paper into a relatively low density pad-like cushioning dunnage product. Cushioning conversion machines in use today have included a forming device and a feeding device which coordinate to convert a continuous web of sheet-like stock material (either single-ply or multi-ply) into a three dimensional cushioning product, or pad. The forming device is used to fold, or roll, the lateral edges of the sheet-like stock material inward on itself to form a strip having a width substantially less than the width of the stock material. The feeding device advances the stock material through the forming device and it may also function as a crumpling device and a connecting (or assembling) device. The cushioning conversion machine may also include a ply separating device for separating the plies of the web before passing through the former, and usually a severing assembly, for example a cutting assembly for cutting the strip into sections of desired length.  
         [0006]     Published European Patent Application No. 94440027.4 discloses a cushioning conversion machine wherein the feeding device comprises input and output pairs of wheels or rollers which operate at different speeds to effect, along with feeding of two plies of paper, crumpling and assembling of the paper plies to form a connected strip of dunnage. The cushioning conversion art would benefit from improvements in the machine shown in such application, and such improvements may have applicability to other cushioning conversion machines as well.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention provides an improved cushioning conversion machine and related methodology characterized by one or more features including, inter alia, a feeding/connecting assembly which enables an operator to easily vary a characteristic, for example the density, of the cushioning product; a feeding/connecting assembly wherein input and/or output wheels or rollers thereof are made at least in part of an elastomeric or other friction enhancing material, which reduces the cost and complexity of the input and output rollers; a manual reversing mechanism that is useful, for example, for clearing paper jams; a modular arrangement of a forming assembly and feeding/connecting assembly in separate units that may be positioned remotely from one another, as may be desired for more efficient utilization of floor space; a turner bar which enables alternative positioning a stock supply roll; and a volume expanding arrangement cooperative with the feeding/connecting assembly for reducing the density of the cushioning product and increasing product yield. The features of the invention may be individually or collectively used in cushioning conversion machines of various types. These and other aspects of the invention are hereinafter summarized and more fully described below.  
         [0008]     According to one aspect of the invention, a cushioning conversion machine, for making a cushioning product by converting an essentially two-dimensional web of sheet-like stock material of at least one ply into a three-dimensional cushioning product, generally comprises a housing through which the stock material passes along a path; and a feeding/connecting assembly which advances the stock material from a source thereof along said path, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning. The feeding/connecting assembly includes upstream and downstream components disposed along the path of the stock material through the housing, at least the upstream component being driven to advance the stock material toward the downstream component at a rate faster than the sheet-like stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form a strip of cushioning. Additionally, at least one of the upstream and downstream components includes opposed members between which the stock material is passed and pinched by the opposed members with a pinch pressure; and a tension control mechanism is provided for adjusting the amount of pinch pressure applied by the opposed members to the stock material. In one embodiment of the invention, the tension control mechanism includes an accessible control member outside the housing for enabling easy operator adjustment of the pinch pressure, whereby a characteristic of the strip of cushioning can be varied on demand. In another embodiment, the upstream and downstream components each include opposed members between which the stock material is passed and pinched by the opposed members with a pinch pressure; and a tension control mechanism is provided for adjusting the amount of pinch pressure applied to the stock material by the opposed members of the downstream component independently of the pinch pressure applied to the stock material by the opposed members of the upstream component, whereby a characteristic of the strip of cushioning can be varied.  
         [0009]     According to another aspect of the invention, a cushioning conversion machine again generally comprises a housing through which the stock material passes along a path; and a feeding/connecting assembly which advances the stock material from a source thereof along the path, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning. The feeding/connecting assembly includes upstream and downstream feeding components disposed along the path of the stock material through the housing, the upstream feeding component being driven to advance the stock material toward the downstream component at a rate faster than the sheet-like stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form the strip of cushioning. An adjustable speed control mechanism is provided for varying the ratio of the feeding speeds of the upstream and downstream feeding components, whereby a characteristic of the strip of cushioning can be varied. In a preferred embodiment, the adjustable speed control mechanism can include, for example, a variable speed drive device (such as a variable pitch pulley system0 for one of the upstream and downstream components, a quick change gear set, or a variable speed control for at least one of respective drive motors for the upstream and downstream components.  
         [0010]     Preferably, a control member is provided outside the housing for enabling easy operator adjustment of the speed ratio, whereby a characteristic of the strip of cushioning can be varied on demand.  
         [0011]     According to a further aspect of the invention, a cushioning conversion machine again generally comprises a housing through which the stock material passes along a path; and a feeding/connecting assembly which advances the stock material from a source thereof along the path, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning. The feeding/connecting assembly includes upstream and downstream components disposed along the path of the stock material through the housing, at least the upstream component being driven to advance the stock material toward the downstream component at a rate faster than the sheet-like stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form a strip of cushioning. Also provided is a stretching component downstream of the downstream component that is operative to advance the strip of cushioning at a rate faster than the rate at which the stock material passes from the downstream component to effect longitudinal stretching of the strip of cushioning.  
         [0012]     According to yet another aspect of the invention, a cushioning conversion machine again generally comprises a housing through which the stock material passes along a path; and a feeding/connecting assembly which advances the stock material from a source thereof along the path, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning. The feeding/connecting assembly includes upstream and downstream components disposed along the path of the stock material through the housing, at least the upstream component being driven to advance the stock material toward the downstream component at a rate faster than the sheet-like stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form a strip of cushioning. At least one of the upstream and downstream components includes opposed members between which the stock material is passed and pinched by the opposed members with a pinch pressure; and at least one of the opposed members is at least partially made of an elastomeric material at a surface thereof engageable with the stock material.  
         [0013]     According to a still further aspect of the invention, a cushioning conversion machine generally comprises a housing through which the stock material passes along a path; and a feeding/connecting assembly which advances the stock material from a source thereof along the path, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning. The feeding/connecting assembly includes at least one rotatable member rotatable in a first direction for engaging and advancing the stock material along the path, a feed motor for driving the one rotatable member in the first direction, and a crank coupled to the rotatable member for enabling rotation of the one rotatable member in a second direction opposite the first direction. In a preferred embodiment the crank is coupled to the rotatable member by a one-way clutch.  
         [0014]     According to yet still another aspect of the invention, a cushioning conversion machine comprises first and second units having separate housings whereby the first and second units can be located at spaced apart locations. The first unit includes in the housing thereof a former for folding the sheet-like stock material to form flat folded stock material having a plurality of layers each joined at a longitudinally extending fold to at least one other layer. The second unit includes in the housing thereof an expanding device operative, as the flat folded stock material passes therethrough, to separate adjacent layers of the flat folded stock material from one another to form an expanded strip of stock material, and a feeding/connecting assembly which advances the stock material through the expanding device, crumples the expanded stock material passing from the expanding device, and connects the crumpled strip to produce a strip of cushioning. In a preferred embodiment, the units are used in combination with a table to form a packaging system, the table including a table top having a packaging surface. The first and second units may be both located beneath said packaging surface, and one may be supported atop the other. In alternative arrangement, the first unit may be located beneath the table top and the second unit may supported on the table top.  
         [0015]     According to another aspect of the invention, a cushioning conversion machine generally comprises a supply assembly for supplying the sheet-like stock material; and a conversion assembly which converts the sheet-like stock material received from the supply assembly into a three-dimensional strip of cushioning. The stock supply assembly includes a support for a supply of the stock material from which the stock material can be dispensed, and a turner device which acts on the stock material to turn the stock material from a first planar orientation at its entry end to a second planar orientation at it exit end perpendicular to the first planar orientation.  
         [0016]     According to a further aspect of the invention, a cushioning conversion machine comprises a forming assembly through which the sheet-like stock material is advanced to form the stock material into a three-dimensional shape and a feeding/connecting assembly that advances and crumples the formed strip, and connects the crumpled formed strip to produce a strip of cushioning. The forming assembly includes a forming member and a converging chute cooperative with the forming member to cause inward rolling of the edges of the stock material to form lateral pillow-like portions of a formed strip, and the feeding/connecting assembly includes upstream and downstream components disposed along the path of the stock material through the machine, at least the upstream component being driven to advance the stock material toward the downstream component at a rate faster than the sheet-like stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form a strip of cushioning.  
         [0017]     According to yet another aspect of the invention, a cushioning conversion machine comprises a feeding/connecting assembly which advances the stock material from a source thereof along a path through the machine, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning. The feeding/connecting assembly includes upstream and downstream feeding components disposed along the path of the stock material through the housing, the upstream feeding component being driven continuously to advance continuously the stock material toward the downstream feeding component during a cushioning formation operation, and the downstream feeding component being driven intermittently to advance periodically the stock material. Accordingly, when the downstream feeding component is not driven the stock material will be caused to crumple longitudinally between the upstream and downstream feeding components, and when driven the longitudinally crumpled stock material will be advanced by the downstream feeding component toward an exit end of the machine.  
         [0018]     According to a still further aspect of the invention, a method for making a cushioning product, by converting an essentially two-dimensional web of sheet-like stock material of at least one ply into a three-dimensional cushioning product, generally includes the steps of supplying the stock material, and using an upstream component of a feeding/connecting assembly to advance the stock material toward a downstream component of the feeding/connecting assembly at a rate faster than the stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form the strip of cushioning, the upstream and downstream components including opposed members between which the stock material is passed and pinched by the opposed members with a pinch pressure. In one embodiment, the method includes the step of adjusting the amount of pinch pressure applied by the opposed members of the downstream component independently of the pinch pressure applied to the stock material by the opposed members of the upstream component to the stock material, whereby a characteristic of the strip of cushioning can be varied. In another embodiment, method includes the step of varying the ratio of the feeding speeds of the upstream and downstream feeding components, whereby a characteristic of the strip of cushioning can be varied.  
         [0019]     The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]      FIG. 1  is a schematic side view of a cushioning conversion machine according to the present invention, with parts removed and broken away to permit viewing of internal machine components.  
         [0021]      FIG. 2  is a schematic plan view of the cushioning conversion machine of  FIG. 1 .  
         [0022]      FIG. 3  is a sectional view of a feeding/crumpling assembly employed in the conversion machine.  
         [0023]      FIG. 3A  is a fragmentary view showing a gear in the drive train.  
         [0024]      FIG. 4A  is an edge view of a top input roller.  
         [0025]      FIG. 4B  is a side view of the top input roller of  FIG. 4A .  
         [0026]      FIG. 4C  is an edge view of a bottom input roller.  
         [0027]      FIG. 4D  is a side view of the bottom input roller of  FIG. 4C .  
         [0028]      FIG. 4E  is an edge view of a top output roller.  
         [0029]      FIG. 4F  is a side view of the top output roller of  FIG. 4E .  
         [0030]      FIG. 4G  is an edge view of a bottom output roller.  
         [0031]      FIG. 4H  is a side view of the bottom output roller of  FIG. 4G .  
         [0032]      FIG. 5A  is schematic side view of a cushioning conversion machine including a different forming assembly.  
         [0033]      FIG. 5B  is a schematic plan view of the cushioning conversion machine of  FIG. 5 .  
         [0034]      FIG. 6A  is a schematic plan view of the Figures/crumpling assembly of  FIG. 3 .  
         [0035]      FIG. 6B  is a side view of the feeding/crumpling assembly of  FIG. 3 , looking from the line  6 B- 6 B of  FIG. 6A .  
         [0036]      FIG. 6C  is a cross-sectional view of the feeding/crumpling assembly of  FIG. 3 , looking from the line  6 C- 6 C of  FIG. 6A .  
         [0037]      FIG. 7  is a side view of a variable pitch pulley system drive.  
         [0038]      FIG. 8  is a side view of the feeding/crumpling assembly of  FIG. 3 , modified to include a tension adjust knob.  
         [0039]      FIG. 9  is a front end view of the feeding/crumpling assembly of  FIG. 8 .  
         [0040]      FIG. 10  is a schematic view illustrating a feeding motor reverse assembly.  
         [0041]      FIG. 11A  is a schematic plan view of a modular converting unit, with parts removed and broken away to permit viewing of internal machine components.  
         [0042]      FIG. 11B  is an end view of an expanding device employed in the modular converting unit of  FIG. 11A , the device being shown with flat-folded stock material expanded thereby.  
         [0043]      FIG. 11C  is a side view of the expanding device of  FIG. 11B , without the stock material.  
         [0044]      FIG. 12  is schematic plan view of a modular forming unit useful with the modular converting unit of  FIG. 11 , with parts removed and broken away to permit viewing of internal machine components.  
         [0045]      FIG. 13  is a side elevational view of a packaging system comprising a packaging table and the modular forming and converting units of FIGS.  11  and  12 , with parts removed and broken away to permit viewing of internal machine components.  
         [0046]      FIG. 14  is a side elevational view of another packaging system comprising another arrangement of a packaging table and the modular converting and forming units of  FIGS. 11 and 12 , with parts removed and broken away to permit viewing of internal machine components.  
         [0047]      FIG. 15  is a side elevational view of still another packaging system comprising another arrangement of a packaging table and the modular converting and forming units of  FIGS. 11 and 12 , with parts removed and broken away to permit viewing of internal machine components.  
         [0048]      FIG. 16  is a side elevational view of a further packaging system comprising another arrangement of a packaging table, the modular forming unit of  FIG. 12 , and another form of modular converting unit, with parts removed and broken away to permit viewing of internal machine components.  
         [0049]      FIG. 17  is a partial plan view of the upstream end of a cushion conversion machine showing a turner bar for use with an upright supply roll.  
         [0050]      FIG. 18  is a side elevational view of the upstream end of the cushioning conversion machine of  FIG. 17  showing further details of the turner bar.  
         [0051]      FIG. 19A  is a plan view of a modified feeding/connecting assembly including an additional set of feeding rollers for stretching the strip of cushioning passing from the upstream set of feeding rollers.  
         [0052]      FIG. 19B  is a side elevational view of the modified feeding/connecting assembly of  FIG. 19A  looking from the line  19 B- 19 B.  
         [0053]      FIG. 19C  is cross-sectional view of the modified feeding, crumpling connecting assembly of  FIG. 19A  taken along the line  19 C- 19 C.  
         [0054]      FIG. 20  is a side elevational view of another modified form of feeding/connecting assembly.  
         [0055]      FIG. 21  is an end elevational view of the modified feeding/connecting assembly of  FIG. 20 . 
     
    
     DETAILED DESCRIPTION  
       [0056]     The references herein to downstream and upstream are made in relation to the movement direction of the stock material through the machine. It will also be appreciated that references to top and bottom, upper and lower, etc. are made in relation to an illustrated orientation of the machine to describe positional relationships between components of the machine and not by way of limitation, unless so indicated. The present invention also embodies the various combinations of any one feature of the invention with one or more other features of the invention, even though shown in separate embodiments.  
         [0057]     Referring now to the drawings in detail, and initially to  FIGS. 1 and 2 , an exemplary cushioning conversion machine  100  is illustrated. The machine  100  has at its rear end (to the left in  FIG. 1 ), a holder  101  for a supply, such as a roll R, or rolls, of sheet-like stock material. The stock material preferably consists of plural, for example two, plies or layers of biodegradable and recyclable sheet-like stock material such as 30 to 50 pound Kraft paper rolled onto a hollow cylindrical tube. The illustrated exemplary machine  100  converts the stock material into a continuous strip of cushioning having, for example, lateral accordion-like portions separated by a thin central band. This strip is connected (assembled) generally along its central band to form a cushioned strip of cushioning product that may be severed, e.g. cut, into sections, or pads, of a desired length.  
         [0058]     The machine  100  includes a housing  102  having a base plate or wall  103 , side plates or walls  104 , and an end plate or wall  105  which collectively form a frame structure. The base wall  103  is generally planar and rectangular in shape. The housing  102  also includes a top cover  106 , which together with the base, side and end walls, form an enclosure.  
         [0059]     The base and side walls  103  and  104  have at the upstream end of the housing inturned edge portions forming a rectangular border around a centrally located, and relatively large, rectangular stock inlet opening  107 . This border may be viewed as an end plate or wall extending perpendicularly from the upstream edge of the base wall  103 . It should be noted that the terms “upstream” and “downstream” are herein used in relation to the direction of flow of the stock material through the machine  100 . The end plate  105  extends perpendicularly from a location near, but inward from, the downstream end of the base wall  103 . The end plate  105  is generally rectangular and planar and includes a dunnage outlet opening.  
         [0060]     The housing (or frame)  102  also includes a front cover or plate  108  which extends perpendicularly from the downstream edge of the base wall  103 . Thus, the end plate  105  and front plate  108  bound upstream and downstream ends of a box-like extended portion of the downstream end of the housing  102 . The front plate  108  may be a door-like structure which may be selectively opened to access cutting assembly components of the cushioning conversion machine  100 .  
         [0061]     The machine  100  further includes a stock supply assembly  109 , a forming assembly  110 , a feeding/connecting assembly  111  powered by a gear drive motor, for example an electric motor  111   a , a severing/aligning assembly  112  powered by a cutter motor, for example an electric motor  112   a  ( FIG. 2 ), and a post-severing or post-cutting guide, and preferably constraining, assembly  113 . The stock supply assembly  109 , including a stock roll axle  114  supported by the holder  101  and guide rollers  115  and  116 , is mounted to an upstream side of the housing  102  or more particularly the upstream end plate or wall  105 .  
         [0062]     The roles the aforesaid assemblies, and components thereof, play in the formation of such a cushioning product are explained below in detail. In regard to the various functions performed by the noted assemblies and components thereof (as well as any other assemblies and components herein described), the terms (including a reference to a “means”) used to identify the herein-described assemblies and devices are intended to correspond, unless otherwise indicated, to any assembly/device which performs the specified function of such an assembly/device that is functionally equivalent even though not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiment of the invention.  
         [0063]     The stock supply assembly  109  in the illustrated machine  100  performs the function of supplying the paper stock material that is to be converted into dunnage. The paper is unwound from the supply roll and passes under the dancer roller  117 . The dancer roller pivots about a pin  118  as the tension on the paper is increased or decreased. The function of the dancer roller  117  is to smooth out the starts and stops of the feeding/connecting mechanism  111  and to help maintain a greater uniformity of tension on the paper.  
         [0064]     The paper then travels over and under two guide rollers  115  and  116 . The function of these rollers is to help guide the paper and maintain uniformity of tension on the paper. The rollers and paper roll axle  114  are supported by two roll brackets  120  and  121  (of the holder  101 ), which are fixedly attached to the main frame of the machine  100 .  
         [0065]     The paper may be of two plies that are intermittently glued together with small drops of glue up the center of the paper plies and the glue drops being spaced approximately 1 foot apart. The glue drops may be used to facilitate loading, prevent bagging of the plies, prevent migration of the plies from side to side, and to promote pulling both plies uniformly through the feeding/connecting assembly  111 .  
         [0066]     The forming assembly  110  is located downstream of the stock supply assembly  109  interiorly of the housing and functions to form the stock material into a continuous three-dimensional strip of dunnage having portions of the stock material overlapped along the central region of the strip.  
         [0067]     The forming assembly  110  consists of a folder plate  122 , folder rollers  123  and  124 , and two side chute plates  125  and  126 . The folding plate  122  has a rounded upstream or entry end over which the central region of the paper passes.  
         [0068]     The upstream end of the folder plate  122  is narrower than (preferably approximately about one-third) the width of the paper such that lateral edge portions of the paper overhang the sides of the folder plate  122 . From its upstream end, the folder plate  122  tapers to its narrower downstream end.  
         [0069]     The folder rollers  123  and  124 , mounted on an axle extending between the ends of pivot arms, further encourage the paper to fold down on either side of the folder plate  122 . The folder rollers  123  and  124  preferably have annular flanges at the outer sides thereof which overhang respective side edges of the folder plate  122  for urging downwardly the lateral edge portions of the outer layer overhanging the folder plate  122 . Further downward urging or folding of the lateral edge portions is effected by edge guides  127  and  128  extending generally perpendicular to the folder plate  122  and spaced from respective side edges of the folder surface at a location downstream of the upstream end portion of the folder plate and upstream of the side walls of the folding channel.  
         [0070]     As the paper progresses toward the feeding/connecting assembly  111 , the edges of the side chute plates  125  and  126  begin to guide the paper inwards. The bottom edge of one side of the chute plates is closer to the folder plate  111  than the other. Consequently, this causes the edge of the paper on one side to fold on top of the edge of the paper on the other side. When the paper leaves the folding assembly  110 , it is a loosely folded pad that is approximately the width of the downstream end of the converging channel.  
         [0071]     The feeding/connecting assembly  111  is located downstream of the forming assembly  110  and is mounted on an upstream side of the downstream end plate  105 . On the opposite or downstream side of the downstream end plate  105 , the severing assembly  112  is mounted. The motors are mounted on the base wall  103  which may be provided with a transverse mounting plate  129  which forms part of the base wall or plate  103 . The motors are disposed on opposite sides of the forming assembly  110 . The post-severing guide assembly  113  is located downstream of the severing assembly  112  and it is mounted on the front plate  108 .  
         [0072]     The feeding/connecting assembly  111  in the illustrated machine  100  performs two primary functions. The feeding/connecting assembly  111  connects the overlapped portions of the stock material to help form and maintain the three-dimensional shape of the strip of dunnage. The feeding/connecting assembly  111  also functions to feed stock material through the machine  100 , as by pulling the stock material from the stock supply assembly and through the forming assembly  110 . These functions are carried out by a pair of rotating roller-like members  130 ,  131 ,  132  and  133  described in greater detail below. It will also be appreciated that the feeding/connecting assembly crumples the formed strip of stock material after which it is assembled or connected to prevent separation of the overlapped layers.  
         [0073]     As shown in  FIGS. 1, 2  and  3 , a lower output roller-like member  132  is mounted to a shaft  144  rotatably driven by the feeding motor whereas the lower input roller  130  is driven by interconnection to the lower output roller  132  in gear type relationship to provide, for example, a speed ratio of about 2:1. The two other rollers  131  and  133  are idlers rotatably carried in a floating frame  135  on respective axles. The driven roller-like members  130  and  132  rotate about an axis fixed with respect to the front plate  108  whereas the two others  131  and  133  are carried by the floating frame  135  which is guided by guide slots in side plates  136  and  137  ( FIG. 3 ) for parallel translating movement toward and away from the driven rollers  130  and  132 . As is preferred, the floating frame  135 , and thus the floating roller-like members  131  and  133 , are resiliently biased by a pair of compression springs  138 , which align both floating roller-like members  131  and  132  by way of side bars  141 . The spring force may be adjusted by tightening or loosening the bolts  140  to vary the squeeze force applied by the roller-like members  130 ,  131 ,  132  and  133  to the strip of stock material passing therebetween from the forming assembly  110  to the severing assembly  112 .  
         [0074]     In operation of the machine  100 , the stock supply assembly  109  supplies stock material to the forming assembly  110 . The forming assembly  110  causes inward rolling, folding and shaping of the sheet-like stock material to form lateral pillow-like portions of a continuous strip of cushioning. The feeding/connecting assembly  111  advances the stock material through the machine  100  and also connects the central portion of the band to form a connected dunnage strip. As the connected dunnage strip travels downstream from the feeding/connecting assembly  111 , the severing/aligning assembly  112  severs or cuts the dunnage strip into sections, or pads, of a desired length. The cut pads then travel through the post-severing constraining assembly  113 .  
         [0075]     As shown in  FIGS. 6A-6C , the feeding/connecting assembly  111  includes two sets of rollers, a back input set of rollers  130  and  131  and the output set of rollers  132  and  133 . The input set of rollers  130  and  131  consists of a lower front roller  130  and the upper front roller  131 . The output set of rollers, similarly, includes the lower back roller  132  and the upper back roller  133 . The input set of rollers  130  and  131  rotate at a faster speed than the output rollers  132  and  133 . The speed ratio of the two sets of rollers is dictated by the two gears  141  and  142  which provide, for example, a speed ratio of about 2:1. The lower output roller  132  is rotated by the front drive shaft  143  which is coupled to the feeding motor. The idler gear  134  enables both shafts  143  and  144  to rotate in the same direction.  
         [0076]     Moreover, both of the two input rollers  130  and  131  have a knurled finish on ⅓ of their outer diametric surfaces as shown in greater detail in  FIGS. 4A-4D . The lower input roller is relieved in the center and the upper input roller  131  has a rounded projection at its center. The lower input roller  130  also has alternate reliefs on the knurled surfaces, and the projection of the upper roller top input roller  131  is to alternately pull the paper side to side, thus facilitating the paper to uniformly crumple (first one lateral side, then the other). The center projection on the upper input roller  130  acts as the pivot point of the paper.  
         [0077]     Additionally, the center projection on the upper input roller  130  prevents the paper from sliding beyond a predetermined point—thereby ensuring that the paper does not slide out from the rollers.  
         [0078]     As shown in  FIGS. 4E-4H , the upper output roller  133  is completely knurled and the lower output roller  132  is relieved in the center and has transverse slots alternating with transverse ribs or teeth at its outer sections. The purpose of this set of rollers  132  and  133  is to supply enough back pressure to allow the pad to crumple between the input and output rollers, and allow the thicker pad to exit at a slower rate than the pad enters.  
         [0079]     The top input and output rollers are spring loaded towards the bottom input and output rollers.  
         [0080]     For further information regarding a feeding, crumpling and connecting assembly similar to that just described, reference may be had to U.S. Pat. No. 6,015,374, which is hereby incorporated herein by reference.  
         [0081]     As a cushioned strip travels downstream from the feeding/connecting assembly  111  through the opening it passes through the severing assembly  112  which severs or cuts the strip into sections of a desired length. These cut sections then travel through the post-severing guide assembly  113 , which preferably includes a converging portion  145  and a rectangular constraining tunnel portion  146 . The cushioned strip then emerges from the rectangular tunnel portion  146  where an operator may remove the cushioned strip from the machine  100 . For further details of a severing assembly, reference may be had, for example, to U.S. Pat. No. 5,569,146.  
         [0082]     In accordance with one aspect of the invention, portions of the outer diametric surfaces of the feeding/connecting rollers  130 ,  131 ,  132 , and  133  shown in  FIG. 1  could be manufactured with rubber (neoprene or urethane) rollers thereby reducing the cost and complexity of the rollers and still providing a high level of friction/back-pressure.  
         [0083]     In accordance with another aspect of the invention, a pad with unique characteristics is obtained by employing a different forming assembly in place of the illustrated forming assembly  110 , as shown in  FIGS. 5A and 5B . The forming assembly, indicated at  200 , comprises a converging chute  202  and a former  203 . The chute and former are essentially the as, and thus function similarly, to the like elements shown in U.S. patent application Ser. No. 08/386,355, which is now abandoned, survived by a continuation, U.S. Pat. No. 6,135,939, which is hereby incorporated herein by reference in its entirety.  
         [0084]     According to yet another aspect of the invention, the speed difference between the input rollers  130  and  131 , and the output rollers  132  and  133  can be variably adjusted. By varying the speed difference, the character of the pad can ve varied (such as density, compactness, cushioning ability, etc.). As the speed differential is increased, a stiffer, more dense pad is produced. This type of pad could be used for packaging heavier objects. As the speed differential is reduced, the pad would become less dense, and possibly more pad would be yielded from the roll of paper. This less dense pad could be used with lighter objects.  
         [0085]     The aforementioned variable speed relationship may be accomplished in a variety of ways, for example:  
         [0086]     (1) Quick change gear sets could be employed to produce different types of pads for different packaging requirements. The gearing would be at set interval values and would require the operator to install the different sets.  
         [0087]     (2) Two motors could be used, one to drive the input shaft and the other to drive the output shaft. Either drive motor could have a variable speed which would adjust the ratio between the shafts.  
         [0088]     (3) A variable pitch pulley system could be used directly between the two shafts  143  and  144  (as shown in  FIG. 7 ). This would replace the current gearing. This system would also permit an operator to adjust the ratio between the shafts. More particularly, the variable pitch pulley system includes, as is conventional, a V-belt trained over an SL-sheave on shaft  144  and an MC-sheave on shaft  143 . The MC-sheave is adjusted by rotating a control knob  148  or other suitable means. The control knob  148  should be located at an accessible location preferably outside the housing for permitting easy adjustment of the variable pitch pulley system, thereby to effect a desired change in the density (or other characteristic) of the cushioning strip.  
         [0089]     In accordance with another aspect of the invention, a modified feeding/connecting assembly may employ an operator adjustable pinch pressure control as shown in  FIGS. 8 and 9 , wherein primed reference numerals are used to designate elements corresponding to those designated above by the same but unprimed reference numeral. Adjustment of the pinch pressure applied by the output rollers allows an operator to adjust some of the characteristics of the pad. If the pinch pressure is increased, a stiffer, more dense pad will be produced. Such a pad could be used for packaging heavier objects. As the tension is reduced, the would be become less dense, and possibly more pad would be yielded from the paper roll. This less dense pad could be used to package lighter objects.  
         [0090]      FIGS. 8 and 9  show a layout of a modified feeding/connecting unit  111  with independent tension springs  149  and  150  for the input and output shafts  143  and  142 . The output shaft  142  has an external knob  148  for operator tension adjustment. The tension on the output shaft  142  will effect the type of pad produced. As the tension on the output shaft  142  is increased, it will become more difficult for the pad to exit—causing the paper to crumple more and produce a more dense pad.  
         [0091]     According to still yet another aspect of the invention, as shown in  FIG. 10 , a feeding/crumpler design  111  could be modified by adding a reverse function. Such a function could be a very useful means to clear paper jams. As seen in  FIG. 10 , a clutch  151  and a manual hand crank  152  could be added to a crumpling machine  100 .  
         [0092]     The purpose of the clutch  151  is to provide a means for disconnecting the feeding motor  153  from the drive shaft  154 —thus allowing for more easier cranking. This clutch  151  can be electrically or mechanically applied. In the electrically applied case, the drive motor  153  is normally disengaged from the drive shaft  154 . Only when the motor  153  is running is an electrical signal applied that activates the clutch  151 . In the mechanically applied case, an operator would disengage the clutch  151  before using the hand crank  152 .  
         [0093]     The hand crank  152  can be permanently fixed to the machine  100  as shown, or can be “folded away,” or even removed from the machine  100  during normal operation.  
         [0094]     Referring now to  FIGS. 11-16 , several packaging systems according the invention are illustrated. The packaging systems are characterized by the use of a modular converting unit  171  shown in  FIGS. 11A-11C  and a modular forming unit  172  shown in  FIG. 12 . The converting and forming units can be located remote from one another as may be desired to provide flexibility in developing a packaging system for different application. The units will typically be employed in combination with a packaging table  175  to form a packaging system.  
         [0095]     The converting unit  171  is for the most part identical to the above described conversion machine  100  ( FIGS. 1 and 2 ) except for the elimination of the forming assembly  110  and the stock supply assembly  109 , which permits a reduction in the length of the unit, and the incorporation of an expanding device  173  (shown in  FIGS. 11A-11C  and  13 ). Accordingly, like components are identified by the same reference numerals used above in the description of the machine  100  ( FIGS. 1 and 2 ).  
         [0096]     As seen in  FIG. 11A , the converting unit  171  includes a housing  174  similar to that described in  FIGS. 1 and 2 . Accordingly, the housing  174  forms an enclosure for internal components of the converting unit  171 . Like machine  100 , the converting unit includes a feeding/connecting assembly  111 , a gear drive motor  111   a,  a cutter motor  112   a,  a post-severing guide including tunnel portion  146  and other similar components which work in the manner described above. However, the converting unit  171  further includes a constant entry roll  176  and an expanding device  173 . The expanding device  173  is located downstream of the constant entry roll  176  and upstream of the feeding/connecting assembly  111 . The constant entry roll  176  is mounted for rotation about its axis between a pair of brackets  177  projecting from the upstream end of the housing  174 .  
         [0097]     Referring now to  FIGS. 11B and 11C , details of the expanding device  173  are shown. The expanding device  173  includes a mounting member  178  to which a separating member  180  is joined. The mounting member  178  includes a transverse support or mounting arm  181  having an outwardly turned end portion  183  and an oppositely turned end portion  185  to which the separating member  180  is attached. The outer end portion  183  is mounted to the converting unit&#39;s housing  174  by a bracket  187  and suitable fastening elements  189 . The mounting member  178  may be formed from bar or tube stock, and the cantilevered central portion  191  thereof may be sloped relative to a transverse center plane of the path of the stock material through the converting unit  171 .  
         [0098]     The separating member  180  includes a transverse support  193  and fold expansion elements  195  at opposite ends of the transverse support  193  that are relatively thicker than the transverse support  193 , with respect to the narrow dimension of the stock material. In the illustrated expanding device, the mounting member  178  is formed by a rod or tube, and the fold expansion elements are formed by rollers supported for rotation on the transverse support at opposite ends thereof. The transverse support  193  is attached near one end thereof to the adjacent end portion  185  of mounting member  181  for support in cantilevered fashion.  
         [0099]     The expanding device  173  is designed for use with flat-folded stock material which is formed by the forming unit  172  ( FIG. 12 ). During the conversion process, the layers of the stock material (formed by the edge and central portions of the ply or plies) travel through the expanding device  173 . More particularly, the central portion  196  of the folded stock material travels over the sides of the rollers  197  opposite the mounting arm  181 , while the inner edge  198  portion of the stock material travels in the narrow V-shape or U-shape slot formed between the transverse support  193  and the mounting arm  181  and the other or outer edge portion of the  199  travels over the side of the mounting arm  181  furthest the separating member  180 . As a result, the edge portions are separated from one another and from the central portion, thereby introducing loft into the then expanded material which now takes on a three dimensional shape as it enters the guide chute  198  of the feeding/connecting device  111 .  
         [0100]     Thus, the expanding device  173  is operative to separate adjacent layers of the flat folded stock material from one another as it passes therethrough to form an expanded strip of stock material. For further details regarding an expanding device similar to that just described, reference may be had to U.S. Pat. No. 6,015,374, which is hereby incorporated herein by reference in its entirety.  
         [0101]     Referring now to  FIG. 12 , the forming unit  172  includes a housing  201  which forms an enclosure for interior components of the forming unit. The forming unit  172  includes a forming assembly  110  like that above described in connection with the embodiment of  FIGS. 1 and 2 . The forming assembly functions to fold lateral edge portions of the stock material over a center portion, and the folded stock material passes to a constant exit roll  205  where the folded over portions are brought together to form a flat folded stock material. The constant entry roll  205  is rotatably mounted between a pair of brackets  207  projecting from the upstream end of the housing  201 . The forming unit  172  is shown supported by a plurality of legs; however, the forming unit  172  may be positioned directly on the floor or supported by other suitable means.  
         [0102]     In  FIG. 13 , the converting unit  171  and forming unit  172  are shown arranged with the packaging table  175  to form a packaging system  210 . The table  175  includes a horizontal work platform or table top  181  and support means such as a plurality of legs  183  which support the table top  181 . In the packaging system  210 , the converting unit is supported atop the table top  181 , and the forming unit  172  is shown positioned below the table top. The converting unit  171  may be equipped with plastic feet  178 , or other anti-skid devices, to prevent shifting of the converting unit  171  along the top of the table  175  or other support surface upon which the converting unit  171  rests. The legs  183  (e.g., support means) include or define therebetween an opening  185  through which the downstream end of the forming unit  172  extends outwardly of an edge of the table  175  for supplying the flat folded stock material to the converting unit  171 . As is explained below in greater detail, this arrangement of the converting unit  171 , the forming unit  172  and the table  175  affords for convenient location of the stock material, easy threading of the stock material, and optimizes the use of valuable floor space by the machine.  
         [0103]     A stock supply assembly  212  supplies the paper product to the forming unit  172 . In the illustrated embodiment, the stock supply assembly includes a floor supported stand  213  which supports a roll of paper (or other stock material)  213  mounted on a support. Of course a variety of conventional stock supply assemblies could be utilized for the purpose of supplying paper to the forming unit  172 .  
         [0104]     The paper travels from the supply assembly  212  to the forming unit  172  where it is folded to form flat folded stock material. The flat folded stock material exits from the forming unit  172  at the exit roller  205  and passes to the entry roller  176  of the converting unit  171 . The stock material then passes to the expanding unit  173  where it is expanded as described above and then fed into the feeding/connecting assembly  111  where it undergoes the process described above to form a three-dimensional strip of cushioning.  
         [0105]      FIGS. 14-16  illustrate other packaging systems including other arrangements of the converting unit  171 , forming unit  172  and table  175 .  FIG. 14  shows a packaging system  216  essentially the same as the packaging system  210  shown in  FIG. 13  except that the stock material passes from the constant exit roll  205  to the constant entry roll  176  via a slot  235  in the table top  181 . This arrangement further reduces the amount of floor space occupied by the converting unit  171 , forming unit  172  and table  175  arrangement since the forming unit does not extend beyond the edge of the table as in  FIG. 13 .  
         [0106]      FIG. 15  shows a packaging system  237  wherein the converting unit  171  is situated beneath the table top  181  and on top of the forming unit  172 . This arrangement provides for increased work space on the table surface  187 . Additionally, the 3-dimensional dunnage product is supplied by a chute  238  to an opening  250  in the table top.  
         [0107]      FIG. 16  shows a packaging system  253  having an arrangement similar to  FIG. 13  except that a different form of converting unit  275  is shown. The converting unit  275  does not have a motor-powered severing assembly as does the converting unit  171 . Rather, the converting unit  275  employs a hand operated handle  277  which is movable to actuate a severing assembly for cutting sections of the strip of cushioning. Additionally, the housing  279  is in the form of a two part casing. The other components, such as the expanding device  281  and feeding/connecting assembly  283 , operate in essentially the same manner as described above. For further details of the converting unit  275 , reference may be had to U.S. Pat. No. 6,015,374.  
         [0108]      FIGS. 17 and 18  illustrate another embodiment of the present invention wherein the supply roll  300  is mounted in an upright orientation on a pair of brackets  301  such that the paper is fed to a turner member  303  in a substantially perpendicular manner. Feeding the paper at a substantially perpendicular angle provides adequate tension on the paper to prevent wrinkling or creasing of the paper yet at the same time not providing so much tension on the paper to cause tearing.  
         [0109]     The supply roll  300  is rotatably supported on a spindle  305  which is supported by brackets  301  at cradles  303 . The supply rod  305  is sized to extend relatively loosely through the hollow core tube of the stock supply roll  300 , and the supply rod  305  is sized to be approximately the distance between the two brackets  301  of the turner member  307 . The paper unwinds from the supply roll  300  and enters the forming assembly  309  after passing over the turner member  307 . As the paper passes over the turner member  307  which includes a turner plate  311 , the sides of the paper fold over the turner member wherein the lateral edge portions of the paper overhang the sides of the turner plate  311 . Folder rollers  313  and  315  mounted on an axle  317  further encourage the paper to fold down on either side of the turner plate  311 . The folder rollers  313  and  315  also function in essentially the same manner as described above with respect to rollers  123  and  124  in  FIGS. 1 and 2 .  
         [0110]     In yet another embodiment of the present invention,  FIGS. 19A, 19B  &amp;  19 C illustrate a modified feeding/connecting assembly  355  wherein a third set of rollers  365  and  367  are located downstream of the input and output rollers  357 ,  359 ,  361  and  363 . The input and output rollers operate in essentially the same manner as the rollers  61 ,  63 ,  65  and  67  described above ( FIGS. 1-4 ) to form a strip of cushioning. The third set or stretching rollers  365  and  367  function to stretch the strip of cushioning exiting from the output rollers  361  and  363 . The roller  365  is driven at a faster rate than the crumpled paper exits the output rollers  361  and  363  which in turn effects a stretching action on the crumpled paper in the longitudinal direction. [Do we have any particulars on speed ratios?] 
         [0111]     Referring now to  FIGS. 20 and 21 , an another form of feeding/connecting assembly  375  is illustrated. The assembly  375  includes an indexing gear mechanism  377 . The assembly  375  includes input and output rollers  379 ,  381 ,  383  and  385  wherein the input rollers  379  and  381  are driven continuously while the output rollers  383  and  385  are driven intermittently. That is, the indexing mechanism  377  operates to intermittently rotate the output or downstream rollers  383  and  385  through a partial revolution (such as ¼) for every full revolution of the input or upstream rollers  379 ,  381 . When the output gears are not rotating, the stock material is crumpled as the input roller will continue to advance the stock material towards and against the output rollers. When the output roller are rotated, the crumpled stock material exits therefrom to form the strip of cushioning. As will be appreciated the indexing pattern can be varied to vary a characteristic of the strip of cushioning.  
         [0112]     In the illustrated embodiment, the indexing mechanism  377  includes a Geneva gear mechanism which includes a driver disk  391  with a cam follower  393  is mounted thereon. A 4-slotted disk  395  is mounted parallel to the bottom output roller  3893  so that it may engage with the cam follower  393 . The driver disk  391  is indexed with the upstream bottom roller  379  in a 1:1 relationship so that for every full revolution of the upstream roller  379 , the driver disk  391  will also revolve one revolution. Accordingly, as the driver disk  391  makes one revolution it will cause the 4-slotted disk  395  to rotate ¼ revolution via the cam follower  393  which in turn rotates the downstream rollers  383 ,  385  ¼ revolution.  
         [0113]     Additionally, an operator adjustable tension control  401  could be added in order to adjust various characteristics of the pad. This tension control  401  operates in essentially the same manner as described above in  FIG. 8 .  
         [0114]     While a particular feature of the invention may have been described above with respect to only one of the illustrated embodiments, such feature may be combined with one or more features of the other embodiments, as may be desired and advantageous for any given or particular application.  
         [0115]     Although the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification. The present invention includes all such equivalent alterations and modifications.