Patent Document

RELATED APPLICATION DATA 
     This is a continuation of U.S. patent application Ser. No. 11/250,695 filed Oct. 11, 2005, now U.S. Pat. No. 7,258,657 which is a continuation of U.S. patent application Ser. No. 10/921,701 filed Aug. 19, 2004, now U.S. Pat. No. 6,974,407 which is a divisional of U.S. patent application Ser. No. 09/387,399 filed Sep. 2, 1999, now U.S. Pat. No. 6,783,489, which is a continuation of U.S. patent application Ser. No. 08/983,593 filed Apr. 13, 1998, now U.S. Pat. No. 6,019,715 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 Ser. No. 60/000,496 filed Jun. 26, 1995, all of which are hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     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 
     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. 
     The foregoing and other disadvantages of conventional plastic packaging materials have made paper protective packaging material a very popular alternative. 
     Paper is biodegradable, recyclable and composed of a renewable resource, making it an environmentally responsible choice for conscientious industries. 
     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. 
     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 
     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 layering device which provides for doubling of the layers of sheet material in the converted cushioning product; 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. 
     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. 
     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 system) 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. 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. 
     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. 
     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. 
     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. 
     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. 
     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 layering device which effects folding of the stock material along a fold line parallel to the longitudinal axis of the stock material, thereby in effect doubling the number of layers of the stock material that are converted into a cushioning product. 
     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. 
     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. 
     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, the 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. 
     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 
         FIG. 1  is a top plan view of a cushioning conversion machine according to the present invention, the machine including a housing, stock-supply assembly, a forming assembly, a feeding/connecting assembly, a severing assembly, and a post-severing assembly. 
         FIG. 2  is a schematic side elevational view of the cushioning conversion machine  100 . 
         FIG. 3  is a sectional view of the feeding/connecting assembly of the machine  100  and relevant portions of the machine&#39;s housing. 
         FIG. 3A  is a fragmentary view of a gear of the feeding/connecting assembly and a relevant portion of the machine&#39;s housing. 
         FIGS. 4A and 4B  are edge and side views, respectively, of a component of the feeding/connecting assembly, namely a feed wheel. 
         FIGS. 4C and 4D  are edge and side views, respectively, of a component of the feeding/connecting assembly, namely a support wheel for the feed wheel. 
         FIGS. 4E and 4F  are edge and side views, respectively, of a component of feeding/connecting assembly, namely a compression wheel. 
         FIGS. 4G and 4H  are edge and side views, respectively, of a component of the feeding/connecting assembly, namely a support wheel for a compression wheel. 
         FIG. 5A  is an isolated plan view of the feeding/connecting assembly, along with relevant parts of the machine&#39;s frame or housing. 
         FIG. 5B  is a side view of the feeding/connecting assembly, as seen from the line  5 B- 5 B in  FIG. 5A . 
         FIG. 5C  is a sectional view of the feeding/connecting assembly, taken along line  5 C- 5 C of  FIG. 5A . 
         FIGS. 6A and 6B  are schematic side and plan views, respectively, of another cushioning conversion machine  100  according to the present invention, 
         FIG. 6C  is schematic side view of the forming assembly of the cushioning conversion machine. 
         FIG. 7  is a side view of portions of a modified version of the feeding/connecting assembly of  FIGS. 1-2 . 
         FIG. 8  is a side view of portions of a modified version of the feeding/connecting assembly of  FIGS. 1-2 . 
         FIG. 9  is a sectional view taken along line  9 - 9  in  FIG. 8 . 
         FIG. 10  is a schematic view of portions of a modified version of the feeding/connecting assembly of  FIGS. 1-2 . 
         FIGS. 11A and 12  are schematic plan view of first and second modular unit s of another cushioning conversion machine according to the present invention. 
         FIG. 11B  is an end view of device of the first modular unit, namely an expanding device, the device being shown with flat-folded stock material expanded thereby. 
         FIG. 11C  is a side view of the expanding device of  FIG. 11B , without the stock material. 
         FIGS. 13-15  are side elevation view of three packaging systems according to the present invention which incorporates the cushioning conversion machine shown in  FIGS. 11A and 12 . 
         FIG. 16  is a side elevation view of a packaging system according to the present invention which incorporates a modified version of the second modular unit shown in  FIG. 12 . 
         FIG. 17  is a partial plan view of a modified version of the stock supply assembly of  FIGS. 1-2 . 
         FIG. 18  is side elevation view of the modified version of the stock supply assembly of  FIG. 17 . 
         FIG. 19A  is a plan view of a modified version of the feeding/connecting assembly of  FIGS. 1 and 2 . 
         FIG. 19B  is a side elevation view of the feeding/connecting assembly of  FIG. 19A . 
         FIG. 19C  is a cross-sectional view of the feeding/connecting assembly of  FIG. 19A , the section being taken along line  19 C- 19 C in  FIG. 19A . 
         FIG. 20  is a side elevation view of a modified version of the feeding/connecting assembly of  FIGS. 1 and 2 . 
         FIG. 21  is an end elevation view of the feeding/connecting assembly of  FIG. 20 . 
         FIG. 22  is a plan elevation view of a modified version of the feeding/connecting assembly of  FIGS. 1 and 2 . 
         FIG. 23  is a cross sectional view of the feeding/connecting assembly of  FIG. 22 , the section being taken along line  23 - 23  in  FIG. 22 . 
         FIG. 24  is an end view of the feeding/connecting assembly of  FIG. 22 . 
     
    
    
     DETAILED DESCRIPTION 
     In  FIGS. 1 and 2 , a cushioning conversion machine  100  according to the present invention is shown. The machine  100  converts an essentially two-dimensional web of sheet-like stock material (the thickness thereof being negligible compared to the width and length thereof—thus the phrase “essentially two-dimensional) into a three-dimensional cushioning product of a desired length. The preferred stock material consists of plural 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 to form a roll R of the stock material. More preferably, the stock material consists of two plies of paper which are intermittently glued together with small drops of glue up the center of the paper plies, the glue drops being spaced approximately one foot apart. The preferred cushioning product has lateral accordion-like or pillow-like portions and is connected, or assembled, along a relatively thin central band separating the pillow-like portions. 
     The cushioning conversion machine  100  includes a housing  102  having a base plate or wall  103 , side plates or walls  104 , a downstream end plate or wall  105 , a top cover  106 , and a downstream cover, or wall  107 . The base, side, and end walls  103 - 105  collectively form the machine&#39;s frame structure. The top cover  106 , together with the base, side and end walls  103 - 105 , form an enclosure for the interior assemblies of the machine  100 . (It should be noted that the terms “upstream” and “downstream” in the context of the present application correspond to the direction of flow of the stock material through the machine  100 .) 
     The walls  103 - 107  of the housing  102  are each generally planar and rectangular in shape. The upstream edges of the base wall  103  and sides walls  104  are turned in to form, along with a top bar  108 , a rectangular border defining a centrally located, and relatively large, rectangular stock inlet opening. The rectangular border may be viewed as an upstream end plate or wall extending perpendicularly from the upstream edge of the base wall  103 . The end plate  105  extends perpendicularly from a location near, but inward from, the downstream end of the base wall  103  and defines a dunnage outlet opening. The downstream cover wall  107  is attached to the downstream edges of the base wall  103 , with the side walls  104  and a downstream portion of the top cover  106  forming a box-like enclosure for certain components of the machine  100 . Preferably, the cover wall  107  may be selectively opened to provide access to these components. The downstream portion of the top cover preferably is fixedly secured in place while an upstream portion of the top cover may be in the form of a hinged door which may be opened to gain access to the interior of the housing and particularly the below mentioned forming assembly to facilitate loading of the stock material in a well known manner. 
     The cushioning conversion machine  100  further includes a stock supply assembly  109 , a forming assembly  110 , a feeding/connecting assembly  111 , a severing assembly  112 , and a post-severing assembly  113 . During the preferred conversion process, the stock supply assembly  109  supplies stock material to the forming assembly  110 . The forming assembly  110  causes inward folding of lateral edge portions of the sheet-like stock material into an overlapping relationship. The feeding/connecting assembly  111  advances the stock material through the machine  100  and also crumples the folded over stock material to form a dunnage strip. As the 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 assembly  113 . 
     The stock supply assembly  109  includes support brackets  114  which are laterally spaced apart and mounted to the upstream end of the machine&#39;s housing  102 . The stock supply assembly  109  also includes first and second guide rollers  115  and  116  which are rotatably mounted between the support brackets  114 , and a dancer roller  117  which is pivotally suspended from the support brackets  114  via swing arms  118 . As paper is unwound from the stock or supply roll R, it travels around the dancer roller  117  so that the pull of the paper upward on the dancer roller  117 , combined with the pull of gravity downward on the dancer roller and swing arms  118 , helps maintain a uniform tension on the paper. The paper then travels over and under the two guide rollers  115  and  116  to guide the paper into the forming assembly  110 . 
     The forming assembly  110  consists of a central plate  119 , a pair of fold-down rollers  120 , with folding elements  121  and  122  forming a chute-like passage, or chute, for lateral edge portions of the stock material. The central plate  119  is mounted on a pedestal  123  attached to the base wall  103  and slopes slightly downwardly, and tapers inwardly, going from the upstream end to the downstream end of the central plate. The rollers  120  are mounted on a shaft  124   a  extending between the ends of a pair of swing arms  124   b  that are pivotally connected at their opposite ends to a support bar  124   c  extending between the side walls  104 . The folding elements  121  and  122  are mounted, in a cantilever-like fashion, from a mounting plate  125 . 
     As the paper enters the forming assembly  110 , the central portion of the paper (preferably about ⅓ of the paper width) will be positioned on the central plate  119  and its remaining lateral edge portions (preferably each about ⅓ the paper width) will be urged, or folded, downward by the rollers  120 . As the paper contacts the folding elements  121  and  122 , the folding elements will fold the lateral edge portions of the paper inward one over the other, whereby they will overlap in a folded arrangement. This overlapped paper, or strip, advances to the feeding/connecting assembly  111 . 
     The feeding/connecting assembly  111  includes a support structure  126 , a wheel (or roller) network  127 , a drive system  128 , and a guide chute  129 . The feeding/connecting components  126 - 129  feed the stock material, for example by pulling it from the stock supply assembly  109  and through the forming assembly  110 . The feed/connecting assembly  111  longitudinally crumples the strip of stock material and then connects, or assembles, overlapped portions of stock material together to lock in a desired three-dimensional geometry of the resultant pad. 
     With additional reference to FIGS.  3  and  5 A- 5 C, the support structure  126  includes a pair of vertical side plates  130 , and a horizontal cross bar  131 . The downstream edges of the side plates  130  are coupled to the machine&#39;s housing  102 , and more particularly to the end wall  105 . The cross bar  131  extends between and is secured to the side plates  130 . 
     As best shown in FIGS.  3  and  5 A- 5 C, the wheel network  127  includes a feed (or input) wheel  132 , a support wheel  133  for the feed wheel  132 , a compression (or output) wheel  134 , a support wheel  135  for the compression wheel  134 , and shafts  137 - 140  for each of the wheels  132 - 135 , respectively. The lower wheels  132  and  134  are secured to the shafts  137  and  139 , respectively, and the upper wheels  133  and  135  are rotatably mounted on their shafts  138  and  140 , respectively. 
     During operation of the feeding/connecting assembly  111 , the lower shafts  137  and  139  are positively driven by the drive system  128  to rotate the lower wheels  132  and  134  which will in turn rotate the upper, or “idler”, wheels  133  and  135 . The lower shafts  137  and  139  extend between, and are rotatably journalled in the support side plates  130 . (See FIGS.  3  and  5 A- 5 C.) 
     The upper shaft  140  extends between the side plates  130  and has its opposite ends positioned within a vertical guide slot  130   a  in the corresponding side plate  130 . (See FIGS.  3  and  5 A- 5 B.) The upper shaft  138  has opposite ends thereof terminating short of the side plates. A pair of laterally spaced apart shaft connectors  142  are connected between the upper shafts  138  and  140 , and each shaft connector is attached, at about the middle thereof, to the lower end of a respective suspension pin or member  143 . Each pin extends vertically though a respective guide opening in the cross bar  131  and carries thereon a compression spring  144  interposed between the cross bar and shaft connector. In this manner, the upper or “idler” wheels  133  and  135  will be resiliently biased towards the corresponding lower wheels  132  and  134 , while being able to vertically “float” relative thereto during operation of the machine  100 . 
     As seen in  FIGS. 4A-4D , the wheels  132  and  133  are both generally cylindrical in shape. The feed wheel  132  includes a middle portion  145  separating opposite axial end portions  146 . The middle portion  145  is in the form of an annular groove which, for example, may have an approximately rectangular (as shown) or semi-circular cross section. The cylindrical periphery of the opposite axial end portions  146  is interrupted by flat faces  147 . The flat faces  147  on one end portion  146  are staggered relative to the flat faces on the other end portion  146 . In other words, the flat faces  147  on one axial end portion  146  are aligned with the “non-flat”, or arcuate, knurled areas  148  on the other axial end portion  146 . The support wheel  133  for the feed wheel  132  also includes a middle portion  149  separating opposite axial end portions  150 . The middle portion  149  is in the form of a radially outwardly protruding annular rib which is preferably rounded at its radial outer side, while the end portions  150  have knurled radial outer surfaces. The radial outer surfaces of one or both of the wheels  132  and  133 , or portions thereof, may be manufactured from an elastomeric material, such as rubber (neoprene or urethane) thereby reducing the cost and complexity of the wheels while still providing a high level of friction-enhancement for relatively slip free engagement with the stock material. 
     As seen in  FIGS. 4E-4H , the wheels  134  and  135  are also both generally cylindrical in shape. The compression wheel  134  includes a middle portion  151  separating opposite axial end portions  152 . The middle portion  151  is radially relieved and has a smooth radial surface. The end portions  152  are ribbed to form rectangular, circumferentially spaced apart teeth. The support wheel  135  for the compression wheel  134  includes a continuous, knurled outer diameter surface. The radial outer surfaces of one or both of the wheels  134  and  135 , or portions thereof, may again be manufactured from an elastomeric material such as rubber (neoprene or urethane) thereby reducing the cost and complexity of the wheels while still providing a high level of friction-enhancement for relatively slip free engagement with the stock material. 
     As seen in  FIG. 1 , the drive system  128  for the feeding/connecting assembly  111  includes an electric motor  153 , and motion-transmitting elements  154 - 159  ( FIGS. 3 ,  3 A and  5 A). The motor  153  is mounted to the base plate  103  on one side of the forming assembly  110 . The motion-transmitting elements transfer the rotational power of the motor  153  to the wheel network  127 , or more particularly the lower shafts  137  and  139 . 
     As seen in  FIGS. 3 ,  3 A and  5 A, the motion-transmitting elements include a drive chain  154  and sprockets  155  and  156 . The sprocket  155  is secured to an output shaft  153   a  of a speed reducing gear box  153   b  driven by the motor  153  (See  FIG. 1 ), and the sprocket  156  is secured to the compression wheel shaft  139 . The drive chain  154  is trained around the sprockets  155  and  156  to rotate the compression wheel shaft  139 . 
     The motion transmitting elements  157 - 159  are gears forming a gear train between the compression wheel shaft  139  and the feed wheel shaft  137 . The gear  157  is secured to the end of the compression wheel shaft  139  opposite the sprocket  156 , the gear  158  is rotatably mounted to support side plate  130 , and the gear  159  is secured to an adjacent end of the feed wheel shaft  137 . In this manner, the feed wheel shaft  137  and the compression wheel shaft  139  will rotate in the same direction. However, the gears are selected so that the shaft  137  (and thus the feed wheel  132 ) is rotating at a faster feed rate than the shaft  139  (and thus the compression wheel  134 ). In the illustrated embodiment, the set speed ratio is on the order of about 1.7:1 to about 2.0:1. 
     As seen in  FIGS. 1 and 2 , the guide chute  129  extends from the exit end of the forming assembly  110  to the outlet opening in the housing end wall  105 . In  FIG. 3 , the guide chute  129  can be seen to be substantially rectangular in cross-section. The upstream bottom and/or side edges of the chute preferably flare outwardly to form a funnel or converging mouth inlet  160  ( FIG. 5B ). The top and bottom walls of the guide chute  129  each include an opening  161  through which the wheels  132 - 135  extend into the interior of the guide chute ( FIGS. 5A-5C ). It will be appreciated that the cross-sectional dimensions (i.e., width and height) of the guide chute  129  approximate the cross-sectional dimensions of the cushioning product. 
     The strip formed in the forming assembly  110  is urged into the guide chute  129  through its funnel inlet  160  whereat it is engaged and fed forwardly (or downstream) by the feed wheel  132  and its support wheel  133 . The staggered arrangement of the flat faces  147  on the end portions  146  of the wheel  133  will cause the strip to be fed alternately from each side of its longitudinal axis, instead of just being pulled only axially. That is, the strip will be fed alternately from each side of its longitudinal axis, instead of being pulled only axially. This advance by successive pulls from one side and then the other side back and forth makes it possible to have at the center a surplus of paper with respect to its flat configuration, this surplus being generated by the rib  159  fitting in the mating groove in the wheel  132 . The strip is then engaged by the compression wheel  134  and its support wheel  135 . Because the wheels  134  and  135  are rotating at a slower speed than the wheels  132  and  133 , the strip is longitudinally crumpled between the upstream and downstream pairs of wheels with the latter compressing folds in the strip. (For further information regarding an assembly similar to the feeding/connecting assembly  111 , reference may be had to European Patent Application No. 94440027.4, filed Apr. 22, 1994 and published on Nov. 2, 1995 under Publication No. 0 679 504 A1, which is hereby incorporated herein by reference.) The strip then exits the guide chute  129  and passes through the dunnage outlet opening in the end wall  105 . 
     As the strip exits the feeding/connecting assembly  111  and passes through the dunnage outlet opening in the end wall  105 , the severing assembly  112  severs its leading portion into a desired length. The illustrated severing assembly  112  includes cutting components  162  preferably powered by an electric motor  163  ( FIG. 1 ). The cutting components  162  are mounted on the downstream surface of the end wall  105  are contained within the enclosure closed by the downstream cover  107 . The severing motor  163  is mounted on the base wall  103  on the side of the forming assembly opposite the feed motor  153 . (See  FIGS. 1 and 2 .) A suitable severing assembly is disclosed in U.S. Pat. No. 5,569,146, which is hereby incorporated by reference. The cut sections of dunnage then travel through the post-severing assembly  113 . 
     As seen in  FIGS. 1 and 2 , the post-severing assembly  113  is mounted to the downstream cover  107 . The inlet and outlet of the assembly  113  are aligned with the dunnage outlet opening in the end wall  105 . The post-severing assembly  113  is rectangular in cross-sectional shape and flares outwardly in the downstream direction. As the cut section of the dunnage strip, or pad, emerges from the outlet of the assembly  113 , the pad is ready for use as a cushioning product. 
     Referring now to  FIGS. 17 and 18 , a modified form  109   u  of stock supply assembly is shown. The stock supply assembly  109   u  operates to layer the stock material prior to its entry into the forming assembly  110 . While the stock supply assembly  109   u  could be used with multi-ply stock material to double the number of layers of material, it is preferably used with single-ply stock material, in that it eliminates the need for rewinding single-ply stock material into multi-ply rolls. 
     The stock supply assembly  109   u  includes a pair of support brackets  114   u  which are vertically spaced (as opposed to laterally spaced like the brackets  114 ) and support the stock roll R u  in a vertical orientation (the stock roll will usually be twice as wide as the normal width because the stock material is folded over on itself to provide a two layer web). The stock supply assembly  109   u  further includes a layering plate  1001  which is vertically positioned upstream of the fold-down rollers  120   u , via a bracket suspending it from a pedestal on the base wall  103 . The layering plate  1001  is generally triangular except that it includes a rounded entry edge  1002 . As the stock material is unwound from the roll R u  in a vertical plane and pulled over the layering plate  1001  into the forming assembly  110 , it is folded in half into a web having two layers. This web is positioned in a horizontal plane ready for receipt by the forming assembly  110 . If desired, the stock roll may be supported in a horizontal orientation with its axis oriented perpendicular to the entry path into the forming assembly  110  and an angled turner bar employed between the stock roll and the layering plate to guide the sheet material from a horizontal plane as it is payed off the stock roll to a vertical plane for passage to the layering plate  1001 . It will also be appreciated that a horizontal disposition of the stock roll may also be obtained by rotating the entire machine embodiment of  FIGS. 17 and 18  by 90 degrees about its longitudinal axis. In addition, additional layers may be provided by supplying stock material from one or more additional rollers, as schematically illustrated by the stock roll R v . Two, three or more stock rolls may be used with the other embodiments herein described if desired. 
     According to another aspect of the invention, a modified version of the feeding/connecting assembly  111  may include interchangeable quick change gear sets are provided to provide respective different feed rate ratios between the input and output wheel of the wheel network. These gear sets would be similar to the gears  157 - 159  ( FIG. 5B ), except they would be of different sizes or tooth number to produce a corresponding change in feed rate ratio and thus the pad characteristics as may be desired. By employing appropriate marking on the gear sets corresponding to desired packaging applications, changes in the speed ratio could be accomplished with minimal training on the part of a machine operator by substituting the proper gear set for a given application. As explained herein, the speed ratio between the feed wheel  132  ( FIG. 5C ) and compression wheel  134  affects the characteristics (such as density, compactness, cushioning ability, etc.) of the pad produced during the conversion process. While the set speed ratio provided by the gear train  157 - 159  may be appropriate in many situations, it may be desirable to selectively change this speed ratio to alter pad characteristics Specifically, if the speed differential is increased, a stiffer, more dense pad will be produced for use in, for example, the packaging of heavier objects. On the other hand, if the speed differential is reduced, a less dense pad will be produced (possibly resulting in greater yield from a given amount of stock material) for use in, for example, the packaging of lighter objects. 
     In another modified form of the feeding/connecting assembly, two separate feed motors could be used, one for the feed wheel shaft  137  ( FIGS. 5A and 5C ) and one for the compression wheel shaft  139 . Either or both of the motors could have a variable speed option to allow selective adjustment of the speed ratio. It is noted that if these motors are directly coupled to the shafts  137  and  139 , the need for the motion-transmitting elements  154 - 159  ( FIG. 5A ) would be eliminated. In any event, this modification would eliminate the need for the gear train  157 - 159  ( FIG. 5A ). 
     In another modified version of the feeding/connecting assembly, shown partially in  FIG. 7 , the gear train  157 - 159  ( FIG. 5A ) of the drive system  128   u  is replaced with a variable pitch pulley assembly  1010 . In the drive system  128   u , the variable pitch pulley assembly  1010  controls the speed ratio between the feed wheel shaft  137  and the compression wheel shaft  139 . The illustrated pulley  1010  includes a SL-sheave  1011  coupled to the feed wheel shaft  137 , a MC-sheave  1012  coupled to the compression wheel shaft  139 , and a V-belt  1013  trained therebetween. An adjustment device  1014  allows manual control (via a control knob  1015  preferably positioned outside the machine&#39;s housing for easy access) of the position of the V-belt  1013  on the sheaves  1011  and  1012  to thereby vary the speed ratio between shafts  137  and  139 , in well known manner. 
     Another modified form of the feeding/connecting assembly is shown in  FIGS. 8 and 9  which is designed to provide for a convenient, and even dynamic, selective change in the biasing force between the compression wheel  134  and its support wheel  135 . The support structure  129   t  of the wheel network  127   t  includes a pair of horizontal cross bars  131   a   t  and  131   b   t  which extend between, and are secured to, the side plates  130 . The cross bar  131   a   t  is vertically aligned with the shaft  138  and the cross bar  131   b   t  is vertically aligned with the shaft  140 . 
     A first pair of pins  143   a   t  (similar to the suspension pins  143 ) couple the shaft connectors  142  to the first support cross bar  131   a   t . The pins  143   a   t  extend from the ends of the shaft-connectors  142  adjacent the shaft  138 . Another pin  143   b   t  is coupled to the shaft connectors  142  via a yoke  1020  connected to the ends of the shaft connectors  142  adjacent the shaft  140 . The pin  143   b   t  is attached to the cross bar  131   b   t  via an adjustment device  1021 . The adjustment device includes an adjustable stop  1021   a  into which the pin  143   b   t  is threaded such that rotation of the pin will move the adjustable stop towards and away from the shaft  140 . A spring  1021   b  is interposed between the adjustable stop  1021   a  and the cross member  131   b   t  of the yoke  1020 . Accordingly, rotation of the pin will increase or decrease the biasing force acting on the yoke and in turn on the shaft  140  and wheel  135 , it being noted that the pin is free to rotate relative to the yoke. 
     As is preferred, the end of the pin projecting above the cross bar has secured thereto a knob  1022 . As will be appreciated, the knob provides for easy manual adjustment of the biasing force acting on the shaft  140 . The knob preferably is located external to the machine&#39;s housing, or at least at a conveniently accessible location within the machine&#39;s housing. If the knob  1022  is tightened, the biasing force between the compression wheel  134  and its support wheel  135  will be increased, thereby creating a more dense pad. If the knob  1022  is loosened, the biasing force will be decreased, thereby creating a less dense pad. Dynamic changes could be made while the machine is operating to change pad characteristics “on the fly.” If desired, the knob may be replaced by other drive mechanisms, such as an electric motor that may be remotely controlled for adjustment of the biasing force. 
     The drive system  128   w  of another modified form of the feeding/connecting assembly is shown in  FIG. 10 . The drive system  128   w  includes a reversing device  1030  which allows the reverse movement of the feeding/connecting assembly to, for example, clear paper jams in the machine. The device  1030  includes a clutch  1031  and a hand crank  1032 . The clutch  1031  allows selective disengagement of the shaft of the motor  153   w  from the compression wheel shaft  139 . The hand crank  1032  is coupled to the compression wheel shaft  139  so that, upon disengagement of the motor drive shaft, the shaft  139  may be manually turned in the reverse direction. The hand crank  1032  can be permanently fixed to the machine as shown, or can be “folded away,” or even removed during normal operation. Alternatively, the motor could be reversed to effect reverse movement of the feeding/connecting assembly. 
     Another modified form of the feeding/connecting assembly is shown in  FIGS. 20 and 21 , this assembly incorporating a modified drive system  128   x . In the modified drive system  128   x , the feed wheel shaft  137  (and thus the feed wheel  132  and its support wheel  133 ) is directly driven by the motor  153  at a constant speed. However, the compression wheel shaft  139  (and thus the compression wheel  134  and its support wheel  135 ) are driven intermittently, rather than continuously, by an indexing device  1040  which replaces the gear train  157 - 159 . When the indexed wheels  134  and  135  are not rotating, the stock material is crumpled as the rotating wheels  132  and  133  continue to advance stock material downstream. When the indexed wheels  134  and  135  are rotating, the stock material will be emitted from the feeding/connecting assembly. 
     The indexing device  1040  is a conventional “Geneva” gear mechanism and, in the illustrated device, the compression wheel  134  rotates a quarter of a revolution for every half revolution of the feed wheel  132 . The device  1040  includes a driver disk  1042  mounted to the support wall  130 , a cam pin  1041  mounted to the driver disk  1042 , a gear  1043  coupled to the end of the feed shaft  137 , and a four-slotted disk  1044  coupled to the end of the compression wheel shaft  138 . The driver disk is indexed with the compression shaft  139  so that upon every half revolution of the feed wheel shaft  137 , the driver disk  1042  will also make one revolution. As the driver disk  1042  makes one revolution, it will cause the four-slotted disk  1044  to rotate a quarter of a revolution via the cam pin  1041 . 
     Another modified form  111   y  of the feeding/connecting assembly is shown in  FIGS. 19A-19C . The wheel network  127   y  of this assembly includes a “stretching assembly” comprised of a stretch wheel  1050 , its support wheel  1051 , and corresponding shafts  1052  and  1053 . During operation of the feeding/connecting assembly  111   y , the wheels  1050  and  1051  are rotated at a faster feed rate speed than the wheels  134  and  135  whereby the strip will be “stretched” prior to passing through the outlet opening in the end wall  105 . The wheels  1050  and  1051  may be essentially identical in design and size as the wheels  134  and  135 , respectively. 
     The addition of the wheels  1050  and  1051  necessitates changes in the support structure  126   y , the wheel network  127   y , and the drive system  128   y . The support structure  126   y  includes extended side walls  130   y  each with an additional slot to accommodate the shaft  1053 , and a cross bars  131   y  positioned between each adjacent set of support wheels. In the wheel network  127   y , shaft-connectors  142   y  connect all three shafts  138 ,  140 , and  1053 , and two sets of suspension pins  143   y  couple the shaft-connectors  142   y  to the cross bars  132   y . In the drive system  128   y , gears  1054  and  1055  are added to the gear train, gear  1054  being mounted to the stretch wheel shaft  1052  and gear  1055  being mounted to the side wall  130   y  to convey motion from the gear  157  to the gear  1054 . The gears  1054  and  1055  may be sized so that the stretch wheel  1050  is rotated anywhere between a feed rate speed just slightly faster than the compression wheel  134  to a feed rate speed equal to the feed wheel  132 . Also, although not shown in  FIGS. 19A-19C , the guide chute  129  ( FIGS. 5A-5C ) is preferably elongated and its slots modified to accommodate the wheels  1050  and  1051 . 
     In a further modified form  111   z  of the feeding/connecting assembly shown in  FIGS. 22-24 , a movable barrier  1060  replaces the compression wheel  134 , its support wheel  135 , and the compression wheel shaft  139 . The barrier  1060  is spring biased towards the feed wheel  132  so that as the strip of cushioning is expelled therefrom, it will be restricted by the barrier  1060 , thereby crumpling the strip in a longitudinal direction. As pressure applied by the crumpling strip increases, the spring bias of the barrier  1060  will be overcome, and it will open to allow the crumpled strip to pass through the outlet opening in the end wall  105 . 
     The illustrated barrier  1060  is made from a circular (in cross-section) bar formed into a rectangular loop having rounded corners. The loop is perpendicularly bent at a central portion to form a rounded corner  1061  between an upper portion  1062  and a lower portion  1063  of the barrier  1060 . The corner  1061  of the barrier  1060  is rotatably attached around the shaft  140  (previously used for the support wheel  135 ). When in a rest position, the barrier&#39;s lower portion  1063  extends into the guide chute  129   z  in a downward and downstream sloping direction with its upper portion  1062  extending upwardly therefrom. In the wheel network  127   z , a guide pin  1064  is connected to, and extends horizontally from, cross bar  131 . The pin  1064  is attached at its other end to a bracket  1065  secured to the top portion  1062  of the barrier, and a spring  1064   a  is carried on the pin  1064  and interposed between the bracket  1065  and the cross bar  131 . As the pressure of the crumpling strip increases behind the lower portion  1063  of the barrier, the upper portion of the barrier  1062  will be pushed towards the cross-bar  131  thereby pivoting the lower portion  1063  upward to allow release of the strip. In the guide chute  129   z , the upper slot  161   z  is extended to the downstream edge of the guide chute, which extends beyond the outlet opening in the end wall  105 . (See  FIG. 22 .) The drive system  128   z  is essentially the same as the drive system  128 , except that the gear train  157 - 159  is eliminated. 
     In  FIGS. 6A and 6B , a cushioning conversion machine  200  is shown. The machine  200  converts sheet-like stock material into a three-dimensional cushioning product of a desired length. As with the machine  100 , the preferred stock material for the machine  200  consists of plural 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 to form a roll R of the stock material. However, the stock material would preferably consist of three plies of paper and, in any event, would not be intermittently glued together. As with the machine  100 , the preferred cushioning product of the machine  200  has lateral accordion-like or pillow-like portions and is connected, or assembled, along a relatively thin central band separating the pillow-like portions. 
     The machine  200  is similar to the machine  100  discussed above, and includes an essentially identical housing  202 , feeding/connecting assembly  211 , severing assembly  212 , and post-severing assembly  213 . However, the stock supply assembly  209  and the forming assembly  210  of the machine  200  differ from these assemblies in the machine  100 . 
     The stock supply assembly  209  includes two support brackets  214  which are laterally spaced apart and mounted to the machine&#39;s frame, or more particularly the upstream wall (or rectangular border)  208 . The stock supply assembly  209  also includes a sheet separator  216 , and a constant-entry roller  218 . The sheet separator  216  includes three vertically spaced rollers which extend between, and are connected to, the support brackets  214 . (The number of separator rollers corresponds to the number of plies or layers of the stock material whereby more or less rollers could be used depending on the number of layers.) The constant-entry roller  218  also extends between, and is connected to, the support brackets  214 . 
     As the paper is unwound from the supply roll R, it travels over the constant-entry roller  218  and into the separating device  216 . In the separating device, the plies or layers of the stock material are separated by the separator rollers and this “pre-separation” is believed to improve the resiliency of the produced cushioning product. The constant-entry roller  218  provides a non-varying point of entry for the stock material into the separator  216  regardless of the diameter of the roll R. (Details of a similar stock supply assembly are set forth in U.S. Pat. No. 5,322,477, the entire disclosure of which is hereby incorporated by reference.) 
     The forming assembly  210  includes a shaping chute  219  and a forming member  220 . The shaping chute  219  is longitudinally converging in the downstream direction and is positioned in a downstream portion of the enclosure formed by the machine&#39;s housing. Its entrance is outwardly flared in a trumpet-like fashion and its exit is positioned adjacent the feeding/connecting assembly  211 . The chute  219  is mounted to the housing at the bottom wall  103  and at  221 . 
     The forming member  220  has a “pinched U” or “bobby pin” shape including a bight portion joining upper and lower legs. The lower leg extends to a point approximately coterminous with the exit end of the shaping chute  219 . The rearward portion of the forming member  220  preferably projects rearwardly of the entry end of the shaping chute by approximately one-half its overall length. Also, the radius of the rounded base or bight portion is approximately one-half the height of the mouth of the shaping chute. This provides for a smooth transition from the separating device  216  to the forming member and then into the shaping chute. 
     The lower leg  220   a  of the forming member  220  extends generally parallel to the bottom wall  219   a  of the shaping chute  219 . However, the relative inclination and spacing between the lower leg of the forming member and bottom wall of the shaping chute may be adjusted as needed to obtain proper shaping and forming of the lateral edges of the stock material. Such adjustment may be effected and then maintained by an adjustment device  223  which, as best shown in  FIG. 6C , extends between the legs of the forming member at a point midway along the length of the lower leg, it being noted that the upper leg may be shorter as only sufficient length is needed to provide for attachment of the top wall of the shaping chute. The adjustment device  223  includes a rod  224  having a lower end attached to the lower leg of the forming member  220  by a rotation joint  225  (such as a ball-and-socket joint). The upper threaded end of the rod  224  extends through a threaded hole in the top wall of the shaping chute as well as through a threaded hole in a upper leg of the forming member  220  and is held in place by a nut  224   a  secured to the shaping chute  219 . To adjust the gap between the lower leg of the forming member and the bottom wall of the shaping chute, the top of the threaded rod is turned the appropriate direction. The rod&#39;s top may be provided with a screwdriver slot or wrench flats, to easily accomplish this turning with standard tools. 
     Further details of the preferred chute  219  and shaping member  220  are set forth in U.S. Pat. No. 5,891,009, the entire disclosure of which is hereby incorporated by reference. However, it should be noted that other chutes and shaping members are possible with, and contemplated by, the present invention. By way of example, the chutes and/or shaping members set forth in U.S. Pat. Nos. 4,026,198; 4,085,662; 4,109,040; 4,717,613; and 4,750,896, could be substituted for the forming chute  219  and/or the shaping member  220 . 
     As the stock material passes through the shaping chute  219 , its lateral end sections are rolled or folded inwardly into generally spiral form and are urged inwardly toward one another so that the inwardly rolled edges form a pillow-like portions of stock material disposed in lateral abutting relationship as they emerge from the exit end of the shaping chute. The forming member  220  coacts with the shaping chute  219  to ensure proper shaping and forming of the paper, the forming member being operative to guide the central section of the stock material along the bottom wall of the chute  219  for controlled inward rolling of the lateral side sections of the stock material. The rolled stock material, or strip, then travels to the feeding/connecting assembly  211 . 
     Another cushioning conversion machine  300 , formed from modular units  300   a  and  300   b  according to the present invention, is shown in  FIGS. 11A ,  11 B,  11 C and  12 . The machine  300  converts sheet-like stock material into a three-dimensional cushioning product of a desired length. As with the machines  100  and  200 , the preferred cushioning product of the machine  300  has lateral crumpled pillow-like portions and is connected, or assembled, along a central band separating the pillow-like portions. As with the machines  100  and  200 , the preferred stock material for the machine  300  consists of plural 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 to form a roll R of the stock material. 
     The first modular unit  300   a  includes a housing  302   a  similar to the downstream portion of the housing  102  of the machine  100 . (See  FIG. 11A .) A feeding/connecting assembly  311 , a severing assembly  312  and a post-severing assembly  313 , which are essentially identical to the corresponding assemblies in the machine  100 , are mounted to the housing  302   a  in the same manner as they are mounted the downstream portion of the housing  102 . However, an expanding device  370  occupies the space in the machine housing  102  that had been occupied by the forming assembly  110  and requires less space. (See  FIG. 11A .) Additionally, a guide roller  372  is mounted to the upstream end of the housing  302   a  via brackets  374 . 
     The expanding device  370  includes a mounting member  378  to which a separating member  380  is joined. (See  FIGS. 11B and 11C .) The mounting member  378  includes a transverse support or mounting arm  381  having an outwardly turned end portion  383  and an oppositely turned end portion  385  to which the separating member  380  is attached. The outer end portion  383  is mounted to the housing  302   a  by a bracket  387  and suitable fastening elements. 
     The separating member  380  includes a transverse support  393  and fold expansion elements  395  at opposite ends of the transverse support  393  that are relatively thicker than the transverse support  393 , with respect to the narrow dimension of the stock material. In the illustrated expanding device, the mounting member  378  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  393  is attached near one end thereof to the adjacent end portion  385  of mounting member  381  for support in cantilevered fashion. 
     The expanding device  373  is designed for use with flat-folded stock material which is formed by the second modular unit  300   b . 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  373 . More particularly, the central section of the folded stock material travels over the sides of the rollers  395  opposite the mounting arm  381 , while the inner edge portion of the stock material travels in the narrow V-shape or U-shape slot formed between the transverse support  393  and the mounting arm  381  and the other or outer edge portion of the travels over the side of the mounting arm  381  furthest the separating member  380 . As a result, the lateral end sections are separated from one another and from the central section, thereby introducing loft into the then expanded material which now takes on a three dimensional shape as it enters the guide chute of the feeding/connecting device  311 . Further details of the expanding device  370  are set forth in U.S. Pat. No. 6,015,374, which is hereby incorporated herein by reference in its entirety. 
     The second modular unit  300   b  includes a housing  302   b  similar to the upstream portion of the housing  102  of the machine  100 . (See  FIG. 12 .) A forming assembly  310  is essentially identical to, and is mounted to the housing  302   b  in the same manner as, the corresponding assembly in the machine  100 . However, a stock roll R may be supported by a floor mounted stand or stock roll support  2002 . Additionally, a guide roller  398  is mounted to a downstream end of the housing  302   a  via bracket  399 . 
     A packaging system  2000  incorporating the cushioning conversion machine  300  is shown in  FIG. 13 . In addition to the machine  300 , the system includes a table  2001  and a floor-mounted stock support  2002 . The first modular unit  300   a  is located on top of the table  2001  and the second modular unit  300   b  is located below the table. As the stock material is unwound from the roll R, it travels from the support  2002 , over the plate  119  through the forming assembly  310 , under the guide roller  398  (positioned between the legs of the table), over the guide roller  372 , through the expanding device  370  and into the feeding/connecting assembly  311 . The strip is then severed by the severing assembly  312  and the cut section travels through the post-severing assembly  313 . 
     A modified version  2000   u  of the packaging system is shown in  FIG. 14 . In the packaging system  2000   u , the folded stock material from the unit  300   b  passes through an opening  2003  in the table  2001   u . This arrangement allows a more central positioning of the units  300   a  and  300   b  relative to the table  2001   u  and also protects the folded strip from interference as it travels between the units. 
     Another modified version  2000   w  of the packaging system is shown in  FIG. 15 . In the packaging system  2000   w , the first unit  300   a  is stacked on top of the second unit  300   b  below an elevated (when compared to tables  2001  and  2001   w ) table  2001   w . Additionally, the post-severing assembly  313   w  is curved upwardly towards an opening  2003   w  in the table whereby the cut section of cushioning will be deposited on the table top. This arrangement allows the table top to be clear of all machine components during the production of cushioning products. 
     Another packaging system  2000   x  according to the present invention is shown in  FIG. 16 . This packaging system incorporates a machine  300   x  which is similar to the machine  300  except for its first modular unit  300   a   x . Specifically, the unit  300   a   x  has manual, rather than motor-powered, severing assembly  312   x . Additionally, the housing  300   b   x  is in the form of a two part casing. The other components, such as the expanding device  370  and the feeding/connecting assembly  311 , operate in essentially the same manner as described above. For further details of the unit  300   b   x , reference may be had to U.S. Pat. No. 6,015,374. 
     One may now appreciate that the present invention provides an improved cushioning conversion machine related methodology. 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. Accordingly, 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. 
     It is noted that the position references in the specification (i.e, top, bottom, lower, upper, etc.) are used only for ease in explanation when describing the illustrated embodiments and are in no way intended to limit the present invention to particular orientation. Also, 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.

Technology Category: 4