Patent Description:
In the context of paper-based protective packaging, paper sheet is crumpled to produce the dunnage. Most commonly, this type of dunnage is created by running a generally continuous strip of paper into a dunnage converting station that converts a compact supply of stock material, such as a roll of paper or a fanfold stack of paper, into a lower density dunnage material. The supply of stock material, such as in the case of fanfold paper, is pulled into the converting station from a stack that is either continuously formed or formed with discrete section connected together. The continuous strip of crumpled sheet material may be cut into desired lengths to effectively fill void space within a container holding a product. The dunnage material may be produced on an as-needed basis for a packer. The dunnage is used to fill a container for packaging. Needed is a way to facilitate packaging by changing the direction of the dunnage that is ejected from a converting station. <CIT> discloses a dunnage-producing system which includes a dunnage conversion machine for converting a stock material into a relatively less dunnage product, a supply of stock material, and a guide element for accurately positioning the supply relative to the machine. The conversion machine is rotatable about a substantially vertical axis. The supply of stock material includes a support for the stock material that is movable relative to the conversion machine. The guide element is rotatable with or otherwise fixed relative to the conversion machine. <CIT> discloses a cushioning conversion machine in which an outlet extension is coupled to the machine's outlet in such a manner that is selectively adjustable relative to the outlet to provide a plurality of exit locations for the cushioning products. <CIT> discloses a dispensing table for a cushioning conversion machine. Where the dispensing table is designed so that during operation of the machine, the cushioning product will be deposited on a work platform.

The invention is defined in the independent claims, to which the reader is now directed. Preferred or advantageous embodiments are set out in the dependent claims. Disclosed is a dunnage apparatus, including a converting station and a deflector. The converting station converts a line of high-density supply material into low-density dunnage and ejects the dunnage at an exit in an exit trajectory along a path. The deflector is repositionable with respect to the exit between a first position and at a first angle, in which the deflector is interposed in the path to deflect the ejected dunnage travelling along the exit trajectory into a first deflected trajectory, and a second position. The deflector in the second position is at a second distance from the exit and at the first angle. The deflector in the second position is interposed into the path farther from the exit than in the first position to deflect the ejected dunnage travelling along the exit trajectory to a second deflected trajectory. The deflector is retained in each position during the ejection of the dunnage.

The deflector in the second position can be disposed out of the path to avoid deflecting the dunnage. The converting station can include a housing, and the deflector in the second position can be retracted into the converting station housing. The deflector in the second position can be interposed in the path to deflect the path of the dunnage from the exit trajectory to a second deflected trajectory. The deflector can be repositionable between the first position and the second position by changing the angle of the deflector relative to the path. The deflector can be pivotable between the first and second positions to vary the angle. The deflector can be pivotable about a high-friction hinge. The deflector in the first position can be closer to the exit than in the second position so that the first deflected trajectory begins at a different location than the second deflected trajectory. The deflector can be slidable between the first and second positions. The deflector can be repositionable by sliding the deflection surface towards and away from the exit. The second position can comprise a range of second positions within a zone that extends along the exit trajectory; and the deflector can be slidable to the second position at any location within the zone; and the deflector can be configured to remain in place at the second position, withstanding impact by the ejected dunnage. The converting station can comprise opposed crumpling members that crumple the supply material to convert it into the dunnage and that eject the dunnage from the exit, such that the exit is located at said crumpling members. The dunnage apparatus can be free from components downstream of the deflector, so that the ejected dunnage, after hitting the deflector, falls into a container that is placed within the first deflected trajectory. The dunnage apparatus can include a cutting member disposed downstream of the exit that severs a downstream portion of the ejected dunnage from a portion of the dunnage still held by the converting station. The cutting member can be disposed upstream of the deflector with respect to the exit trajectory. The cutting member can be disposed further from the exit than the deflector in at least one of the first or second positions.

Disclosed is a method, comprising converting a line of high-density material into low-density dunnage at a converting station; ejecting the dunnage from an exit of the converting station in an exit trajectory along a path; positioning and retaining a deflector in a first position with respect to the exit, in which the deflector is interposed in the path to deflect the path of the dunnage from the exit trajectory to a first deflected trajectory; and repositioning and retaining the deflector in a second position with respect to the exit.

The drawing figures depict one or more implementations in accordance with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements;.

Disclosed is a dunnage machine for converting a stock material into dunnage. More particularly, the dunnage machine includes a mechanism for deflecting the dunnage that is ejected from the apparatus, for example, to direct the dunnage into a packaging container. The present disclosure is generally applicable to systems and apparatus where supply material, such as a stock material, is processed.

With reference to <FIG>, and <FIG>, a dunnage conversion system <NUM> is disclosed, including stock material <NUM> and a dunnage apparatus <NUM> for processing the stock material <NUM> to provide dunnage <NUM>. In accordance with various embodiments, the dunnage apparatus <NUM> includes a supply station <NUM> for holding the supply material <NUM> and a dunnage machine <NUM>. The dunnage machine <NUM> comprises a converting station <NUM> that converts the stock material <NUM> into dunnage <NUM> and ejects the dunnage <NUM> at an exit <NUM>. A support <NUM> may be provided that supports the converting station <NUM> at a distance above the ground.

As shown in <FIG>, the dunnage machine includes a deflector <NUM> that is operable to change the trajectory of the dunnage <NUM> exiting the converting station <NUM>. For example, the deflector <NUM> may be operable to aim the dunnage <NUM> into a carton <NUM>, thus facilitating the packaging process. Embodiments of the deflector <NUM> are further discussed below.

The conversion apparatus is operable to convert stock material into dunnage and eject the dunnage in an exit trajectory along a path. The deflector is interposed within the path and is configured to deflect the dunnage from the exit trajectory to a deflected trajectory. The deflected trajectory can direct the dunnage towards the ground at a sharper angle than that of the exit trajectory. Thus, a user can position a container closer to the dunnage apparatus for collecting the dunnage, thereby conserving space in a packaging location.

The stock material may be stored in a roll (whether drawn from inside or outside the roll), a wind, a fan-folded source, or any other form. The stock material may be continuous or perforated. The conversion apparatus is operable to drive the stock material in a first direction, which can be a dispensing direction. The conversion apparatus is fed the stock material from the repository through a drum in a dispensing direction. The stock material can be any type of protective packaging material including other dunnage and void fill materials, inflatable packaging pillows, etc. Some embodiments use supplies of other paper or fiber-based materials in sheet form, and some embodiments use supplies of wound fiber material such as ropes or thread, and thermoplastic materials such as a web of plastic material usable to form pillow packaging material.

The converting station <NUM> operates to convert the stock material <NUM> into dunnage <NUM>, according to various suitable methods. In accordance with various examples, as shown in <FIG>, the stock material <NUM> is allocated from a bulk supply <NUM> and delivered to the converting station <NUM> for converting to dunnage material <NUM>. The converting station <NUM> has an intake <NUM>, through which it receives the stock material, for example, from the supply station <NUM>. The converting station <NUM> incudes a drive mechanism <NUM> that is operable to pull or assist in pulling the stock material <NUM> into the intake <NUM>. In some embodiments, the stock material <NUM> engages an shaping member <NUM> prior to the intake <NUM>.

The drive mechanism <NUM> is able to pull or assist in pulling the stock material <NUM> into the intake <NUM>. The stock material <NUM> begins being converted from dense stock material <NUM> to less dense dunnage material <NUM> by the intake <NUM> and then pulled through the drive mechanism <NUM> and dispensed in a dispensing direction A on the out-feed side <NUM> of the intake <NUM>. The material can be further converted by crumpling, folding, flattening, or other similar methods that further create the low-density configuration.

The stock material <NUM> can be stored as stacked bales of fan-fold material. However, as indicated above, any other type of supply or stock material may be used. The stock material <NUM> can be contained in the supply station <NUM>. In one example, the supply station <NUM> is a cart movable relative to the dunnage conversion system <NUM>. The cart supports a magazine <NUM> suitable to contain the stock material <NUM>. In other examples, the supply station <NUM> is not moveable relative to the dunnage conversion system <NUM>. For example, the supply station <NUM> may be a single magazine, basket, or other container mounted to or near the dunnage conversion system <NUM>.

The stock material <NUM> is fed from the supply side <NUM> through the intake on <NUM>. The stock material <NUM> may be fanfolded, delivered in sheets, provided as a roll of material or similar supply techniques. In some embodiments, the stock material <NUM> comprises continuous or semi-continuous lengths of sheet material allowing for continuous or semi-continuous feeds into the dunnage conversion system <NUM>. Multiple lengths can be daisychained together. Further, it is appreciated that various structures of the intake <NUM> can be used, such as those intakes forming a part of the converting stations disclosed in <CIT>, <CIT>, <CIT>, and <CIT>.

In one configuration, the dunnage conversion system <NUM> can include a support <NUM> for supporting the station. In one example, the support portion <NUM> includes an inlet guide <NUM> for guiding the sheet material into the dunnage conversion system <NUM>. The support portion <NUM> and the inlet guide <NUM> are shown with the inlet guide <NUM> extending from the post. In other embodiments, the inlet guide may be combined into a single rolled or bent elongated element forming a part of the support pole or post. The elongated element extends from a floor base configured to provide lateral stability to the converting station. In one configuration, the inlet guide <NUM> is a tubular member that also functions as a support member for supporting, crumpling and guiding the stock material <NUM> toward the drive mechanism <NUM>. Other inlet guide designs such as spindles may be used as well.

In accordance with various embodiments, the advancement mechanism is an electromechanical drive such as an electric motor <NUM> or similar motive device. The motor <NUM> is connected to a power source, such as an outlet via a power cord, and is arranged and configured for driving the dunnage conversion system <NUM>. The motor <NUM> is an electric motor in which the operation is controlled by a user of the system, for example, by a foot pedal, a switch, a button, or the like. In various embodiments, the motor <NUM> is part of a drive portion, and the drive portion includes a transmission for transferring power from the motor <NUM>. Alternatively, a direct drive can be used. The motor <NUM> is arranged in a housing and is secured to a first side of the central housing, and a transmission is contained within the central housing and operably connected to a drive shaft of the motor <NUM> and a drive portion, thereby transferring motor <NUM> power. Other suitable powering arrangements can be used.

The motor <NUM> is mechanically connected either directly or via a transmission to a drum <NUM>, shown in <FIG>, which causes the drum <NUM> to rotate with the motor <NUM>. During operation, the motor <NUM> drives the drum <NUM> in either a dispensing direction or a reverse direction (i.e., opposite of the dispensing direction), which causes drum <NUM> to dispense the dunnage material <NUM> by driving it in the dispensing direction, depicted as arrows "A" in <FIG>, or withdraw the dunnage material <NUM> back into the conversion machine in the direction opposite of A. The stock material <NUM> is fed from the supply side <NUM> of the intake <NUM> and over the drum <NUM>, forming the dunnage material <NUM> that is driven in the dispensing direction "A" when the motor <NUM> is in operation. While described herein as a drum, this element of the driving mechanism may also be wheels, conveyors, belts or any other device operable to advance stock material or dunnage material through the system.

In accordance with various embodiments, the dunnage conversion system <NUM> includes a pinch portion operable to press on the material as it passes through the drive mechanism <NUM>. As an example, the pinch portion includes a pinch member such as a wheel, roller, sled, belt, multiple elements, or other similar member. In one example, the pinch portion includes a pinch wheel <NUM>. The pinch wheel <NUM> is supported via a bearing or other low friction device positioned on an axis shaft arranged along the axis of the pinch wheel <NUM>. In some embodiments, the pinch wheel can be powered and driven. The pinch wheel <NUM> is positioned adjacent to the drum such that the material passes between the pinch wheel <NUM> and the drum <NUM>. In various examples, the pinch wheel <NUM> has a circumferential pressing surface arranged adjacent to or in tangential contact with the surface of the drum <NUM>. The pinch wheel <NUM> may have any size, shape, or configuration. Examples of size, shape, and configuration of the pinch wheel may include those described in <CIT> for the press wheels. In the examples shown, the pinch wheel <NUM> is engaged in a position biased against the drum <NUM> for engaging and crushing the stock material <NUM> passing between the pinch wheel <NUM> and the drum <NUM> to convert the stock material <NUM> into dunnage material <NUM>. The drum <NUM> or the pinch wheel <NUM> is connected to the motor <NUM> via a transmission (e.g., a belt drive or the like). The motor <NUM> causes the drum or the pinch wheel to rotate.

In accordance with various embodiments, the drive mechanism <NUM> may include a guide operable to direct the material as it is passes through the pinch portion. In one example, the guide may be a flange <NUM> mounted to the drum <NUM>. The flange <NUM> may have a diameter larger than the drum <NUM> such that the material is kept on the drum <NUM> as it passes through the pinch portion.

The drive mechanism <NUM> controls the incoming dunnage material <NUM> in any suitable manner to advance it from a conversion device to the cutting member. For example, the pinch wheel <NUM> is configured to control the incoming stock material. When the highspeed incoming stock material diverges from the longitudinal direction, portions of the stock material contacts an exposed surface of the pinch wheels, which pulls the diverging portion down onto the drum and help crush and crease the resulting bunching material. The dunnage may be formed in accordance with any techniques including ones referenced to herein or ones known such as those disclosed in <CIT>.

In accordance with various embodiments, the conversion apparatus <NUM> can be operable to change the direction of the stock material <NUM> as it moves within the conversion apparatus <NUM>. For example, the stock material is moved by a combination of the motor <NUM> and drum <NUM> in a forward direction (i.e., from the inlet side to the dispensing side) or a reverse direction (i.e., from the dispensing side to the supply side <NUM> or direction opposite the dispensing direction). This ability to change direction allows the drive mechanism <NUM> to cut the dunnage material more easily by pulling the dunnage material <NUM> directly against an edge <NUM>. As the stock material <NUM> is fed through the system and dunnage material <NUM> it passes over or near a cutting edge <NUM> without being cut.

Preferably, the cutting edge <NUM> is curved or directed downward so to guide the material in the out-feed segment of the path as it exits the system near the cutting edge <NUM> and potentially around the edge <NUM>. The cutting member <NUM> can be curved at an angle similar to the curve of the drum <NUM>, but other curvature angles could be used. It should be noted that the cutting member <NUM> is not limited to cutting the material using a sharp blade, but it can include a member that causes breaking, tearing, slicing, or other methods of severing the dunnage material <NUM>. The cutting member <NUM> can also be configured to fully or partially sever the dunnage material <NUM>.

In various embodiments, the transverse width of the cutting edge <NUM> is preferably about at most the width of the drum <NUM>. In other embodiments, the cutting edge <NUM> can have a width that is less than the width of the drum <NUM> or greater than the width of the drum <NUM>. In one embodiment, the cutting edge <NUM> is fixed; however, it is appreciated that in other embodiments, the cutting edge <NUM> could be moveable or pivotable. The edge <NUM> is oriented away from the driving portion. The edge <NUM> is preferably configured sufficient to engage the dunnage material <NUM> when the dunnage material <NUM> is drawn in reverse. The edge <NUM> can comprise a sharp or blunted edge having a toothed or smooth configuration, and in other embodiments, the edge <NUM> can have a serrated edge with many teeth, an edge with shallow teeth, or other useful configuration. A plurality of teeth is defined by having points separated by troughs positioned there between.

As discussed above, any stock material may be used. For example, the stock material may have a basis weight of about at least <NUM> lbs. , to about at most <NUM> lbs. Examples of paper used include <NUM> pound kraft paper. The stock material <NUM> comprises paper stock stored in a high-density configuration having a first longitudinal end and a second longitudinal end that is later converted into a low-density configuration. The stock material <NUM> is a ribbon of sheet material that is stored in a fan-fold structure, as shown in <FIG>, or in coreless rolls. The stock material is formed or stored as single-ply or multiple plies of material. Where multi-ply material is used, a layer can include multiple plies. It is also appreciated that other types of material can be used, such as pulp-based virgin and recycled papers, newsprint, cellulose and starch compositions, and poly or synthetic material, of suitable thickness, weight, and dimensions.

In various embodiments, the stock material includes an attachment mechanism such as an adhesive portion that is operable as a connecting member between adjacent portions of stock material. Preferably, the adhesive portion facilitates daisy-chaining the rolls together to form a continuous stream of sheet material that can be fed into the converting station <NUM>.

Generally, the dunnage material 21moves through the system along a material path A. The material path A has various segments such as the feed segment from the supply side <NUM> and severable segment <NUM>. The dunnage material <NUM> on the out-feed side <NUM> substantially follows the path A as it is ejected from the dunnage machine <NUM>.

<FIG> shows a continuous, yet uncut, length of the dunnage <NUM> being ejected from the exit <NUM> at an exit trajectory TE along a path. <FIG> shows the dunnage machine including a deflector <NUM> that is interposed in the path to deflect the path of the continuous length of dunnage from the exit trajectory TE to a deflected trajectory TD. For example, the deflector <NUM> can bend the path of the dunnage from the exit trajectory TE to the deflected trajectory TD. In the embodiment shown in <FIG>, the deflected trajectory TD is angled downward at a steeper angle than the exit trajectory TE, to direct the continuous length of dunnage <NUM> into container <NUM>, so that simultaneously a portion of the continuous length of dunnage is being converted while another portion of the continuous length of dunnage is being deflected by the deflector. In the embodiment shown in <FIG>, the deflected trajectory aims substantially directly downward, so that dunnage <NUM> is directed into container <NUM> at a location substantially beneath the exit <NUM>. Thus, the deflector <NUM> is operable to aim the dunnage <NUM> into a carton <NUM>, thus facilitating the packaging process. Also, in cases in which the dunnage machine includes a cutting member <NUM> disposed proximate the exit <NUM>, the deflector <NUM> can direct the dunnage towards the cutting member <NUM>, thus facilitating the user in separating the dunnage <NUM> with the cutting member <NUM>.

<FIG> show side views of a dunnage machine, including a converting station that ejects dunnage at an exit <NUM> in an exit trajectory along a path, and a deflector <NUM> that is repositionable with respect to the exit <NUM>. As shown in <FIG> and <FIG>, in some embodiments, when the dunnage <NUM> is ejected from the exit <NUM>, it travels along the exit trajectory TE in the E-direction, and the deflector <NUM> is repositionable between various positions by changing the angle of the deflector <NUM> relative to the E-direction.

In some embodiments, the E-direction is the direction that the dunnage is traveling at the last place of contact within the converting station. The E-direction is typically the direction of the tangent between the crumpling rollers, or the direction in which the dunnage leaves the elements of the converting station that convert the supply material into dunnage, or that move the dunnage out of the dunnage machine.

<FIG> show the deflector <NUM> in two positions that are both interposed in the path and positioned to deflect the dunnage <NUM> from the exit trajectory TE to a deflected trajectory. <FIG> is a side view of the dunnage machine, with a comparison of the exit trajectory TE and the deflected trajectory TDA that can result from the deflector <NUM> positioned as it is shown in <FIG>. <FIG> is a side view of the dunnage machine, with a comparison of the exit trajectory TE and the deflected trajectory TDA that can result from the deflector <NUM> positioned as it is shown in <FIG>.

In <FIG> and <FIG>, the deflector <NUM> comprises a deflecting surface that extends at angle A relative to the E-direction, and deflects the dunnage at a deflected trajectory TDA. In <FIG> and <FIG>, the deflecting surface extends at angle B relative to the E-direction, and deflects the dunnage at another deflected trajectory TDB. As shown, angle A is greater than angle B, causing the deflector <NUM> in <FIG> and <FIG> to deflect the dunnage <NUM> more than in <FIG> and <FIG>. For example, the deflector <NUM> positioned in <FIG> bends the path of the dunnage more than when it is positioned in <FIG>. For example, the deflector <NUM> positioned in <FIG> directs the dunnage <NUM> at a steeper angle downward than in <FIG>.

<FIG> shows the deflector <NUM> positioned so that it extends substantially parallel to the E-direction. Typically, in this position the deflector <NUM> is not interposed in the path of the dunnage <NUM> and does not deflect the path of the dunnage <NUM>. In some cases, however, in this position the deflector <NUM> deflects the dunnage <NUM>, but to a lesser degree than in <FIG>.

<FIG> and 4D show the deflector <NUM> in a retracted position so that it is disposed out of the path and does not deflect the dunnage <NUM>. The converting station <NUM> can have a housing <NUM> that houses the drive mechanism, and the deflector <NUM> is retracted into the housing.

The deflector <NUM> can be repositionable by way of various suitable methods. In the embodiment shown in <FIG>, the deflector <NUM> is pivotable (e.g., about a hinge) between the various positions to change the angle of the deflector <NUM> relative to the exit, and thereby change the angle of the deflecting surface relative to the E-direction. In some embodiments, the deflector <NUM> is pivotable to any position within its pivotable range. In other embodiments, the deflector <NUM> is pivotable to a number of predetermined positions. The deflector can be retained in a position by way of various suitable methods, such as by friction, a ratchet, or a latch.

With reference to <FIG> and <FIG>, in some embodiments, the deflector <NUM> is part of a deflection member <NUM> that also includes a base member <NUM> for supporting deflector <NUM>. <FIG> and <FIG> show deflector <NUM> pivotable relative to a base member <NUM> about hinge <NUM>. The hinge can retain deflector <NUM> in a position with sufficient strength so that the deflector <NUM> maintains its position, withstanding the force of dunnage that is launched against it by the converting station. The hinge <NUM> may be a high-friction hinge. Additionally or alternatively, the hinge <NUM> may have a latch or other type of mechanical locking mechanism. In preferred embodiments, the deflector <NUM> is pivotable about the hinge <NUM> and remains in position, withstanding the force of the dunnage <NUM> that is deflected therefrom. In some embodiments, the dunnage machine <NUM> is configured so that a user can pivotally reposition the deflector <NUM> about the hinge <NUM> with his or her hand.

As shown in <FIG> and <FIG>, in some embodiments, housing <NUM> includes a guide <NUM> and the deflection member <NUM> is moveable along the guide <NUM> to move the deflector <NUM> between an extended position (e.g., shown in <FIG>) to a retracted position (e.g., shown in <FIG>). The guide can extend along the interior of left and right sidewalls <NUM>, <NUM> of housing <NUM>. The guide <NUM> can comprise two left and right tracks extending between an outer end <NUM> and an inner end <NUM>, and the deflection member <NUM> can be slidable along the tracks between an outer and inner ends <NUM>, <NUM> to slide the deflector <NUM> relative to the exit <NUM>. As shown in <FIG>, <FIG>, and <FIG>, the deflector <NUM> can pivot be to a position so that top and bottom surfaces of the deflector <NUM> are aligned with top and bottom surfaces of base member <NUM>. Thus, the deflection member <NUM> can slide along the guide <NUM> so that a substantial portion of the deflector <NUM> is contained within the housing <NUM>. The housing <NUM> can have a cover <NUM> extending above the left and right sidewalls <NUM>, <NUM>, so that the deflection member <NUM> is substantially contained within housing <NUM> when in a retracted position. For example, in the retracted position, the deflection member <NUM> can be entirely contained within the housing <NUM> except for a handle portion <NUM> that is exposed out of deflector slot <NUM>. Preferably, the housing <NUM> also covers the pinch wheel <NUM>.

In embodiments, the deflection member <NUM> moves in other suitable ways besides sliding. For example, the interior of the housing side walls <NUM>, <NUM> can have notches at various locations relative to the exit, and the deflector <NUM> can be repositionable by a user removing the deflection member <NUM> from a first notch and inserted it into a different notch.

In some embodiments, the extended position comprises a range of extended positions within a zone that extends along the guide, and the deflector <NUM> is slidable or otherwise movable to an extended position at various locations within the zone, such as anywhere within the zone, and retainable in those locations. In other embodiments, the deflector <NUM> is slidable or otherwise movable to a finite number of predetermined positions.

As shown in <FIG> and <FIG>, deflector <NUM> can be magnetically held in the retracted position by a magnetic engagement. In some embodiments, magnet <NUM> on the housing <NUM> magnetically interacts with a ferrous material that is disposed on the exterior of the base member <NUM> or contained therewithin. For example, the base member <NUM> can have an interior that contains a magnet <NUM>, which is attracted to the magnet <NUM> on the housing. The magnetic interaction between the magnets <NUM>, <NUM> can be sufficiently strong to keep the deflector <NUM> in a retracted position. Magnet <NUM> can be positioned on the housing <NUM> adjacent the inner end <NUM> of the track guide <NUM> or in other suitable locations to maintain magnetic engagement with magnets <NUM> on the base member <NUM>. The magnetic attraction can be strong enough to hold the base member <NUM> and deflector <NUM> in position, until a user grasps the deflector <NUM> with his/her hand. Other embodiments can use other mechanisms to retain the base member in retracted position, such as a mechanical locking mechanism.

The deflector <NUM> can include a handle portion <NUM> that extends from the housing <NUM> in the retracted position or that is otherwise accessible. Thus, a user can grasp the handle portion <NUM> and pull deflector <NUM> to disengage the magnetic attraction with magnet <NUM> and pull deflector <NUM> to an extended position. In some embodiments, in the retracted position, a substantial portion of the deflector is contained within the housing <NUM> and only the handle portion <NUM> extends from the housing <NUM>.

Other embodiments can have other suitable mechanisms to deploy or move the deflector <NUM> to various positions. For example, the deflection member <NUM> can comprise a ratchet. A gear can be disposed within the guide <NUM>, and the base member <NUM> can have one or more pawls for interacting with the gear. A simple ratchet mechanism that can be used includes a sprung finger that rides over teeth to retain the deflector <NUM> in one of several incremental positions and allow it to be overcome by hand by pushing in either direction.

The deflection member <NUM> can have a stop <NUM> that abuts the outer end <NUM> of the guide <NUM> in the extended position. The deflection member <NUM> can be biased in an extended position. For example, the dunnage machine <NUM> is free from a member that secures the deflection member <NUM> in the extended position. In other embodiments, an attachment mechanism (e.g., a magnet on housing <NUM> proximate outer end <NUM>) secures the deflection member <NUM> in the extended position. In preferred embodiments, when positioned in the extended position, the deflection member <NUM> remains in the extended position, withstanding the force of dunnage <NUM> that contacts the deflector <NUM>.

Referring now to <FIG>, in some embodiments, deflector <NUM> is repositionable relative to the exit <NUM> to various positions that are interposed in the path to deflect the dunnage. For example, the deflector can be repositionable towards and away from the exit <NUM> in the E-direction. <FIG> show deflector <NUM> positioned in a near position, intermediate position, and distal position, respectively. As shown in the embodiment of <FIG>, the length of the dunnage is greater than the distance between the deflector and the exit to simultaneously convert a portion of the length of dunnage while another portion of the length of dunnage is being deflected.

In some embodiments, the near, intermediate, and distal positions are included within a zone that extends along a direction (e.g., the E-direction), and the deflector <NUM> is slidable to an extended position at any location within the zone. For example, the deflector can be positionable in an infinite number of positions within the zone.

In other embodiments, the deflector <NUM> is slidable to a number of predetermined positions (e.g., the near, intermediate, and distal positions only). For example, the deflection member <NUM> can comprise a ratchet. A gear can be disposed within the guide <NUM>, and the base member <NUM> can have one or more pawls for interacting with the gear. A simple ratchet mechanism that can be used includes a sprung finger that rides over teeth to retain the deflector <NUM> in one of several incremental positions and allow it to be overcome by hand by pushing in either direction.

As shown in <FIG> and <FIG>, the dunnage machine <NUM> can comprise a static remover <NUM> that removes static buildup from the dunnage <NUM>. Further details of a static remover are provide in <CIT>, entitled "Dunnage Apparatus with Static Remover".

In some instances, the static remover <NUM> contacts the dunnage <NUM> without interrupting the path of the dunnage <NUM> (e.g., without bending the path of the dunnage <NUM>). The static remover <NUM> can be configured to contact dunnage <NUM> sufficiently to remove static, without changing the trajectory of the dunnage <NUM>. For example, the static remover <NUM> can be configured so that the dunnage glides against a contact side of the static remover <NUM>. In other instances, the static remover <NUM> contacts the dunnage <NUM> and bends the path of the dunnage <NUM>. The static remover can be interposed in the path to deflect the path of the dunnage <NUM> from the exit trajectory to a deflected trajectory.

In instances in which both the static remover <NUM> and deflector <NUM> are interposed in the path of the dunnage <NUM>, the static remover <NUM> can deflect the dunnage path from the exit trajectory to a first deflected trajectory, and the deflector <NUM> can deflect the dunnage path from the first deflected trajectory to a second deflected trajectory. Additionally or alternatively, the interposition of both the static remover <NUM> and the deflector <NUM>, together in the dunnage path, operates to deflect the dunnage from the exit trajectory to a deflected trajectory.

Deflection of the dunnage, by one or more of the static remover <NUM> or the deflector <NUM>, can direct the dunnage into a packaging container, thereby facilitating the packaging process.

The deflector <NUM> shown in <FIG> is part of deflection member <NUM> that is similar to the abovedescribed deflection member <NUM>. Deflection member <NUM> includes a base <NUM>, which can be similar to the abovedescribed base <NUM>. For example, the deflection member <NUM> can interact with guide member <NUM> on the housing <NUM> to move relative to exit <NUM>. In some embodiments, deflection member <NUM> differs from the above-described deflection member <NUM> in that it does not include the forward stop <NUM> (see <FIG> and <FIG>). Thus, rear stop <NUM> abuts the exterior end <NUM> of guide <NUM> in the distal position (e.g., <FIG>). An intermediate stop can be positioned on the base between stops <NUM>, <NUM>, and the guide <NUM> can have a catch, for example, to help retain the deflection member <NUM> in an intermediate position (e.g., <FIG>). The engagement between the intermediate stop and catch can be configured to allow a user to overcome the engagement, for example, by pushing or pulling the deflection member <NUM> by hand. For example, the catch can comprise a bump within the guide <NUM>, and the intermediate stop can be configured to move around the bump by a user applying some force by hand.

In some embodiments, in addition to the deflector <NUM> being repositionable along a direction (e.g., along the E-direction), the deflector <NUM> is also repositionable at various angles relative to the exit <NUM>. For example, the deflector <NUM> can also pivot relative to the exit <NUM> (as shown in <FIG>).

Referring now to <FIG>, in preferred embodiments, the dunnage machine <NUM> comprises a cutting member <NUM> disposed downstream of the exit <NUM> that severs a downstream portion of the ejected dunnage <NUM> from a portion of the dunnage still held by the converting station. In some embodiments, the cutting member <NUM> is disposed upstream of the deflector <NUM> with respect to the exit trajectory. In some embodiments, the cutting member <NUM> is disposed further from the exit than the deflector in at least one of the first or second positions. Preferably, the deflector <NUM> is disposed proximate the cutting member <NUM> to deflect the dunnage in a way to assist a user in cutting the dunnage <NUM> against the cutting member <NUM>.

As shown in <FIG> and <FIG>, the converting station <NUM> can have a pinch wheel <NUM> that is repositionable between an engaged position (<FIG>) and a released position (<FIG>). Converting station housing <NUM> can have a pressing portion <NUM> that houses the pinch wheel <NUM> biased against the drum <NUM> for crushing the stock material <NUM> passing between the pinch wheel <NUM> and the drum <NUM> to convert the stock material <NUM> into dunnage material <NUM>. The pinch wheel <NUM> can be biased against the drum by way of a magnetic engagement. For example, a first magnetic member <NUM> can be arranged on the pressing portion <NUM> for interacting with a second magnetic member <NUM> on a lower housing portion <NUM>. The first magnetic member <NUM> may be magnetically coupled, such as by magnetic attraction, to the second magnetic member <NUM> sufficiently to require a predetermined force tending to separate the pinch wheel <NUM> from the drum <NUM> to overcome the magnetic coupling. Forces tending to separate the rollers may occur, for example, if a paper jam occurs between the pinch wheel <NUM> and the drum <NUM>. Once the magnetic counting is overcome, the bias of the pinch wheel <NUM> towards the drum <NUM> may be decreased or eliminated due to the proximity between the magnets decreasing. As such, removal of the jam or simply opening the device for servicing may be facilitated. Some exemplary embodiments of magnetic configurations can be found in <CIT>, entitled "Center-Fed Dunnage System Feed and Cutter.

Deflector <NUM> is attached to the pressing portion <NUM>, so that the deflector <NUM> is repositionable along with the drum <NUM>. Thus, when the pressing portion <NUM> is in the released position, for example to facilitate maintenance on the converting station, then the deflector <NUM> also moved out of the way.

In embodiments in which the converting station <NUM> comprises a static remover <NUM>, the static remover <NUM> may be attached to the pressing portion <NUM>, so that the static remover <NUM> is repositionable along with the wheel <NUM>. For example, both the dunnage deflector <NUM> and the static remover <NUM> can both be repositionable together between engaged and releases positions along with the pinch wheel <NUM>.

Claim 1:
A dunnage apparatus (<NUM>), comprising:
a converting station (<NUM>) that converts a line of high-density supply material (<NUM>) into low-density dunnage (<NUM>) and ejects the dunnage (<NUM>) at an exit (<NUM>) into an exit trajectory along a path; and
characterized in that a deflector (<NUM>) is mounted repositionably downstream of the exit (<NUM>) at a first angle with respect to the exit (<NUM>), the deflector (<NUM>) being repositionable between:
a first position at a first distance from the exit (<NUM>) and at the first angle, in which the deflector (<NUM>) is interposed into the path of the exit trajectory to deflect the ejected dunnage (<NUM>) traveling along the exit trajectory into a first deflected trajectory, and
a second position at a second distance from the exit (<NUM>) and at the first angle, in which the deflector (<NUM>) is interposed into the path farther from the exit (<NUM>) than in the first position to deflect the ejected dunnage (<NUM>) traveling along the exit (<NUM>) trajectory to a second deflected trajectory,
wherein the deflector (<NUM>) is retained in each of the first position or the second position during the ejection of the dunnage (<NUM>).