Cushioning conversion machine and method.

MACHINE AND METHOD FOR CUSHIONING CONVERSION

DESCRIPTION OF THE INVENTION

The invention described herein relates generally to a machine that creates packaging, such as a cushioning converting machine for producing a packaged or palletized product from a sheet-like supply material provided, for example, in roll form, and more particularly to an improved modular construction of such a machine, which allows, among other things, the provision of a low-cost machine for low-volume users.

In the process of shipping an item from one location to another, protective packing material is typically placed inside the shipping container, or box, to fill any gaps and/or cushion the item during transit. Some common protective packing materials include small (peanut-shaped) pieces of foam plastic and bubble wrap. Although these conventional plastic materials seem to work adequately as cushioning products, they are not without drawbacks. Perhaps the most serious disadvantage of plastic bubble wrap and/or small pieces of plastic foam is

L 111 and its effect on our environment. Quite simply, these plastic packaging materials are not biodegradable and thus exacerbate the already critical waste disposal problems on our planet. The non-biodegradability of these packaging materials has become increasingly important as many industries adopt more progressive policies regarding environmental responsibility.

The aforementioned disadvantages and other drawbacks of conventional plastic packaging materials have made paper a very popular protective packaging alternative. Paper is biodegradable, recyclable, and renewable, making it an environmentally responsible choice for conscious industries. In addition, the protective paper packaging material is particularly advantageous for use with particle-sensitive mechanics, as its dust-free, clean surface is resistant to static adhesion.

Although sheet paper could potentially be used as a protective packaging material, it is usually preferable to convert the paper sheets into a cushion-like product or other relatively low-density packaging product. This conversion can be accomplished by a cushioning converting machine, such as those described in U.S. Patents Nos. 4,968,291 and 5,123,889, commonly assigned. They describe cushioning converting machines that convert 5 sheet-like supply or provision material, such as multi-fold paper, into a cushion-like packaging product having longitudinally extending pillow-like portions that are joined together along a stitched central portion 10 of the product. The preferred provisioning material consists of three overlapping layers of biodegradable Kraft paper weighing thirteen point sixty-two kilograms (thirty pounds), reusable and recyclable, wound into a hollow cylinder tube. A 76.2 cm (15) wide roll of this paper, which is approximately 136.8 m (450 ft) long, will weigh approximately 15.89 kilograms (35 lbs) and will provide cushioning equal to approximately four zero point three cubic meter (fifteen 20 cubic ft) bags of plastic foam fragments, while at the same time requiring less than one thirtieth of storage space.

Specifically, these machines convert the supply material into a continuous, unconnected strip 25 that has pillow-like, lateral portions

-41 lili.

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-5sot.^a -οοτρορθά ap or oppou un ap aquauipenueui opebnuue psded ap or jopadns espoq tun apsap opB¿qsTinuins oq^ns ouappau ouioo peq^zuopuaque edtuds; ep ap uamnpoA oCeq ap a Ce tequia ap seopqoeud sep uod OApqTqaduioo oqsoo ap sa anb eupnbem eun uepnopqued ua opuaÁnpoup^zuamnpoA oCeq ap OE sauoTDtnqis ua jopaque op ua sepeuopouaui seupnbem seuauipud se^ anb eppTpeqompe euispui ep uTonpoud eued aquauieoTinouooa ssamnqn uapand sapeno sep 'ο^θβτρ squaui^Tqpqsi osad ap Á sappqequod seupnbpm ap ouqsTUTiuns pe aquaiuuepnopqued ' seuiSTUi ts uod ueAapp anbune 'soduq. sotiea ap SP aCepequia ueauo enb seupubem ua aquauieAuqoapoo o penpTAtpuu asuezupuqn uapand uotdu3aut ep ap seoTqsTjraqoejceo seq - uppoa Cnsuaqup ap ouispueoaui un Á aCequom pa jzeiuuop Á upiiij:ojuod ap euiJioj eAanu eun ' aquawpenuem opeuopDoe aquoo ap ouiSTueoaui Á uoponquauippe^Zepezpqpun OP epppqono ap aCequom un opuaÁnpaup 'oqsoo oCeq ap aquoa ap aíequoui un Á sajropjcaquT saquauoduioo sop e PP^ej osaooe 'apqpxapj osn pa eued ^epnpoui uoponjqsuoD eun 'shsod sejiqo aiqus 'opuaÁnpoup 'sEDTqsuaqDPieo sep^eA uod epezpuaqoeueo epeuopoepau ejbopopo^aui Á oAanu aCepnquia un ñauo g anb eumbeui eun euoTOUodoud upTouaAUT aquasaud eq • oqe 'uoTonuedau X oquaTiUTuaquieui ap ρηρτρτουρ 'oqsoo uouaui OpeuoCam oquoTuieuopounp aquauipeuauab opueuopouodoud seuoCaui spiu uapquieq ouioo The 'sapTqpquod' aspects of the invention will be summarized below and described more fully below.

According to one aspect of the invention, a cushioning conversion machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises first and second units having separate housings. The first unit includes in its housing a forming member on which the sheet-like supply material is shaped into a three-dimensional form. The second unit includes in its housing a feeding mechanism for extracting the supply material onto the forming member of the first unit. The housings of the first and second units, respectively, have an outlet opening and an inlet opening positioned relative to each other to provide a path for the transfer of sheet-like material from the first unit to the second unit.

In a preferred embodiment, the first and second units can be arranged in a plurality of relative positional relationships, and their accommodations can be separably interconnected. The accommodations of the first and second units can have

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Respective coplanar lower supports for butting a support surface, or in an alternative arrangement, one of the first and second units may be supported by wheels for movement towards and away from the other unit. In the latter case, cooperative guide members in the housings of the first and second units may be provided for the relative positioning of the first and second units when carried together. In any case, the first and second units 10 may be oriented vertically, horizontally, or in any other way. The second unit may include a frame and an outer cover enclosing the frame; the latter includes an outlet duct for the guided and restricted flow of the packaging product out of the second unit 15.

As also preferred, a manually releaseable connection is provided between the first and second units, such as in the form of a slip-fit ​​connection. The slip-fit ​​connection 20 holds the units together against separation in a longitudinal direction, while allowing separation in a transverse direction. The sliding fit connection includes a protrusion on one of the units and a groove on the other unit to slide the protrusion and preferably a device.

manually releaseable closing devices, such as a hand-tightening screw and the like, to close the units together against separation in the transverse direction.

According to another aspect of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises a forming member on which the sheet-like supply material is drawn to form the supply material into a three-dimensional shape, a feeding mechanism for extracting the provision material onto the forming member and an outer cover forming inside it a cooperative converging conduit with the forming member to roll the edges of the provision material to form the pillow-like, lateral portions. The cover includes a base portion and a removable cover portion, and preferably, the forming member is carried by the removable cover.

In a preferred embodiment, adapted for use with the supply material having multiple folds, the base portion of the outer cover has laterally separated side walls, and a plurality of spacer members are mounted and extend between the side walls for use in

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Separate the folds from the multi-fold provision material. The cover may be hinged to the base portion for swinging between open and closed positions, or the cover may be removably secured to the base portion by pins or similar fasteners. The base portion of the preferred cover has flat bottom supports to butt a support surface and, as preferred, the base portion and cover are molded from plastic.

According to another aspect of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises a forming member on which the sheet-like supply material is drawn to form the supply material into a three-dimensional shape, A feeding mechanism for extracting the supply material onto the forming member and a cutting assembly for cutting the cushioned packaging product into cutting sections. The cutting assembly includes a blade assembly and an operator assembly for operating the blade assembly. The blade assembly includes a guide frame and a pair of relatively movable blades mounted on the guide frame for the

-1010 relative movement and separating from each other, and the guide frame is removably mounted to the machine independently of the operator assembly, so the blade assembly can be removed without having to remove the operator assembly.

In a preferred embodiment, the operator assembly includes a handle member movable in a first direction to move the blades together and in a second direction to move the blades apart. The operator assembly further includes at least one slotted crank connected to the handle for rotation in opposite directions in response to movement of the handle in the first and second directions, respectively. The blades include at least one moving blade mounted on the guide frame for movement towards and away from the other blade, and a bolt is connected to the moving blade and engaged in a slot in the slotted crank for movement of the moving blade in response to rotation of the slotted crank. The groove 20 in the slotted crank is open at one end to allow removal of the bolt in a direction parallel to the groove when the blade assembly is removed from the machine. The slotted crank is connected to a crankshaft, and the handle can be connected to the crankshaft in any of 25 or a plurality of mounting positions.

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As preferred, the handle is movable in the second direction to a feed position in which the blades move relatively far apart to allow the passage of the packaged product 5 between them and in the first direction to a full cutting position sufficient to cut the packaged product to form a cut piece. The feeding mechanism includes at least one rotating member for coupling and advancing the supply material, a drive motor 10 for driving the rotating member, and a control member operatively connected to the drive motor for controlling the energizing and de-energizing of the drive motor. The control member is functionally related to the handle, such that movement 15 of the handle in the second direction to the feed position energizes the drive motor and movement of the handle in the first direction de-energizes the drive motor.

The invention also provides a 20-blade assembly for use in a cushioning converting machine for cutting a continuous strip of packaging into separate pieces. The blade assembly comprises a guide frame and a pair of blades mounted for relative movement on the guide frame. The guide frame includes a moving blade carriage and a guide

-1212 for guiding the transverse movement of the moving knife carriage and the moving knife carriage includes, preferably at each end thereof, a cam pin that can be engaged in a groove of the slotted crank 5 and cooperating with it to effect the movement of the moving knife carriage in response to the movement of the slotted crank.

• The invention also provides a stitch-stitch assembly, adapted for use in a cushioning converting machine 10, which converts the sheet-like material into a relatively low-density cushioning packaging product. The stitch-by-stitch assembly comprises a frame, a pair of shafts mounted to the frame with at least one of the shafts being transversely movable towards and away from the other shaft, and a pair of gear wheel members, Swivels carried for the rotation of the shafts and adapted to be placed in a geared condition to engage the sheet-like material as the latter passes between the members, and at least one spring-operated deflection means on one shaft to push the shaft and the gear member carried thereon toward the other shaft and the gear member elastically to retain the gear members in an interlocked relationship with the sheet-like material between them. The means of

-13L1ILL spring deflection includes a connecting member that extends transversely with respect to a shaft and is anchored at one end to a fixed support on the frame, an adjustable retainer on the connecting member and adjustable 5 along its length towards and away from a shaft, and a spring member interposed between a shaft and the adjustable retainer to elastically deflect one shaft towards the other shaft.

In a preferred embodiment, a shaft has an opening through which the connecting member extends, and the spring member includes a helical member supported on the connecting member. Preferably, a pair of spring deflection means are provided at opposite ends of a shaft, the frame 15 includes laterally separated side members between which the shafts extend, and the connecting members of the pair of spring deflection means are anchored to the frame by laterally separated brackets, fixed to the side members, respectively.

According to yet another embodiment of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises a forming member onto which the sheet-like supply material is extracted to

-14; 111.1, forming the supply material into a three-dimensional shape and a feeding mechanism for extracting the supply material onto the forming member of the first unit, the feeding mechanism including at least one rotating member for coupling and advancing the supply material, and an operating member mounted for reciprocating motion and operatively connected to the rotating member, to rotate the rotating member during the movement of the operating member from a first position to a second position and during the return movement of the operating member from the second position to the first position.

In a preferred embodiment, a one-way clutch device connects the rotating member to the operating member, which preferably includes a mounted handle for back-and-forth oscillating motion.

Integrated into this arrangement is a cutting assembly for cutting the cushioning packaging product into cutting sections. The cutting assembly includes a pair of relatively movable blades. The operating member is movable from the first position, moving from the second position to a third position to move the blades together, and from the third position to the second position to move the blades apart. A first gear is connected to a rotating member and a second

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The Lili 11 gear is connected to the operator member. This second gear has a toothed segment for intermeshing with the first gear during operator movement, between the first and second positions, and a non-toothed segment to pass over the teeth of the first gear during operator movement, between the first and third positions. A one-way clutch device preferably connects the first gear to the rotating member.

According to yet another aspect of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises a forming member onto which the sheet-like supply material is drawn to form the supply material into a three-dimensional shape, a feeding mechanism for drawing the supply material onto the forming member, A converging conduit cooperating with the forming member to roll the edges of the provision material to form pillow-like portions, sides, and a forming member having a U-shape with a first leg attached to an upper wall of the conduit and a second leg extending into the conduit generally parallel with a lower wall of the conduit. In one embodiment

-1616 Preferred, the base of the U-forming member is curved and projects tangentially with the second leg forward from the converging conduit. The forming member may also be of uniform width, and an adjustment device may be provided to adjust the clearance between the second leg and the lower wall of the converging conduit. The adjustment device is preferably connected between the first and second legs. As also preferred, the upper and lower walls of the converging duct 10 are generally flat, and the converging duct has curved side walls that extend between the upper and lower walls. The second leg of the preferred forming member extends to a point adjacent to the outlet opening of the converging duct.

According to yet another aspect of the invention, a cushioning converting machine is provided in combination for converting the sheet-like material into a relatively low-density cushioning packaging product and a platform for retaining the machine.

0 Vertical. The platform comprises a vertical support to which the machine is mounted and a base extending in opposite directions from the vertical support to butt a horizontal surface. The base includes laterally spaced supports to hold the ends of a clamp for a feed material roller. In a

-1717 Preferred modality, the vertical support and the base are interconnected by telescope members, the telescope members are interlocked with a sliding fit, so that the base can be easily separated from the vertical support without disassembling the machine from the support. Preferably, the base is formed by a pair of laterally separated legs each connected to a <¹¹ Vertical support by telescope members, the telescope members are interlocked with a 10 slide adjustment, so the leg can be easily separated from the vertical support and each leg includes a respective support from the laterally separated supports.

According to yet another aspect of the invention, a cushioning conversion machine is provided in combination to convert the sheet-like material into a relatively low-density cushioning packaging product and a stand to retain the machine, the machine and the stand having cooperating hooks and pins, which retain the machine to the stand. In a preferred embodiment, the hooks and pins, which may include cotter pins and mating cotter pin holes, are disengaged by the relative movement of the machine and the support in a first direction for removal of the machine from the platform, and a release clamping device is

-1818 provides for preventing such relative movement of the machine and the support. The preferred movable clamping device is manually releaseable without the aid of a tool.

5. In addition, according to a preferred embodiment, the support comprises a frame on which the machine is mounted and a base for butting against a horizontal surface. The base includes laterally spaced support members for supporting the ends of a clamp for a roll of supply material. The base can be connected to the frame by sliding telescopic members, which allow the base to be removed from the frame and replaced by a suspension hook that includes laterally separated supports to support the ends of a clamp for a roll of supply material, so that the machine can be supported, for example, butted up on a table in a horizontal orientation. preferably with the frame that is equipped with non-slip devices such as suction cups to keep the frame on top of the table.

With regard to a preferred embodiment of the machine that includes the aforementioned feeding and forming units, which have separate housings, the hooks and pins include a first hook and pin for attaching the first unit to the support.

-19Lililí and the second hook and pin to retain the second unit to the support. Preferably, the first hook and pin include a suspension hook extending transversely over the first unit and a frame member extending transversely from the support. As will be seen, the machine can be hanging from the support in a cantilever-like manner by the cooperating hooks and pins, and more particularly, the first and second units can be hanging from the support in a cantilever-like manner by the first hook and pin and the second hook and pin, respectively.

According to yet another aspect of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises a former through which the sheet-like supply material is advanced to form the supply material into a three-dimensional shape; a feeding mechanism for advancing the material of

0 provisioning through the former; a cutting assembly; for cutting the cushioning packaging product into cutting sections, the cutting assembly includes at least one blade movable from a first position that allows the provisioning material to advance through a

5 cutting zone to a second position to cut the

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LUI 11 cushioning packaging product in the cutting area; and a movable retaining member between an enabling position, which allows movement of the blade from the first position to the second position and a disabling position, which prevents movement of the blade from the first position to the second position. In a preferred embodiment, the cutting assembly includes an actuating member operatively connected to a blade, such that the actuating member moves from a third position to a fourth position in a blade-driving direction, It moves the blade from the first position to the second position, and the retaining member is mounted on the machine for movement between a retaining position, which allows movement of the actuating member from the third position to the fourth position, and an interference position, which blocks movement of the actuating member from the third position to the fourth position. Preferred, the retaining member includes a machine-mounted bolt for axial movement between the enable and disable positions, and the bolt is deflected toward the enable position. The plurality of retaining surfaces are spaced along the bolt axis, and the bolt has a transaxially extending butt contact surface selectively engageable with the

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Llil 1¡.

Retaining surfaces to define the plurality of axially displaced positions of the bolt, or at least one of the positions corresponding to the enabling position of the retaining member and another of the positions corresponding to the disabling position of the retaining member.

According to another aspect of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises a former through which the sheet-like supply material is advanced to form the supply material into a three-dimensional shape; a feeding mechanism for advancing the supply material through the former; a blade assembly for cutting the cushioning packaging product into cutting sections, the blade assembly includes at least one movable blade for cutting the cushioning packaging product; and an operator assembly. The operator assembly includes a pair of cranks that operatively couple opposite ends of the blade assembly, such that rotation of the cranks effects the movement of a movable blade, and a handle having opposite ends each operatively connected to a respective crank of the cranks to rotate the cranks.

-22Lililí by the movement of the handle. At least one end of the handle is adjustable relative to the respective crank, so that the operator assembly can be aligned with the blade assembly. In a preferred embodiment, each end of the handle is rotationally adjustable relative to the respective crank. More particularly, the cranks are secured to axially aligned pivot axes, respective for rotation with them. The handle has at each end a protrusion for attachment to a hub on a respective pivot shaft, and at least one fastener is used to secure the mounting to the hub, the fastener passing through an opening in one of the protrusion and the hub and the opening being circumferentially elongated relative to the axis of the respective pivot shaft to provide rotational adjustment of the handle relative to the crank.

According to yet another aspect of the invention, a cushioning converting machine for converting sheet-like material into a relatively low-density cushioning packaging product comprises first and second units having separate housings each containing respective cooperating assemblies for converting the sheet-like material into a three-dimensional, relatively low-density cushioning packaging product. the accommodations of the

-2323 first and second units respectively, have an outlet opening and an inlet opening positionable relative to each other to provide a path for transferring sheet-like material from the first unit to the second unit and wherein the first and second units have a sliding fit connection between the first and second units, The sliding fit connection holds the units together against separation in a longitudinal direction, while allowing separation in a transverse direction. In a preferred embodiment, the sliding fit connection includes a projection on one of the units and a groove on the other unit to slide into the projection. Ideally, the other unit includes a backplate and an outer cover that has a backing wall that forms the groove with the backplate.

According to yet another aspect of the invention, a cushioning converting machine A for converting a sheet-like material into a cushioning packaging product of relatively low density is provided with a cover enclosing a forming assembly through which the sheet-like material is passed to form it into a three-dimensional shape. The cover has a back wall and

-24Lili 11 opposite side walls formed by the respective corners of the deck with the back wall. The supply supports are secured to the deck at the corners; the supply supports have lower and upper end portions; the lower portions are separated laterally to support between them a sheet-like supply of material, and the upper portions are generally L-shaped with the legs of the L secured respectively to the back wall and the respective side wall. In a preferred embodiment, the lower portion of each provisioning holder includes a vertically upward opening slot to receive the end of a fastener for a roll of the sheet-like material.

According to another aspect of the invention, a cushioning conversion machine is provided in combination to convert the sheet-like material into a relatively low-density cushioning packaging product and a platform to hold the machine vertically. The machine and the platform have a principal transverse plane passing through the center of gravity of the machine and the platform, and the platform has a lower surface for butting against a horizontal surface, defining a support platform between them. The platform also includes at least one

-2525 roller displaced vertically from the support plane and displaced horizontally from the transverse plane and a pivot is provided for coupling the horizontal surface to form a pivot point around which the machine and base can be made to oscillate in the direction of the horizontal displacement of a roller. The roller is positioned to engage the horizontal support surface before the center of gravity of the machine and the platform has been rotated 20 beyond a vertical plane that intersects the support point, so that by engaging the roller with the horizontal surface, the machine and the platform can be rolled along the horizontal surface. In a preferred embodiment, the roller is positioned to engage the horizontal support surface before the center of gravity of the machine and platform has rotated 10° beyond the vertical plane. A stop may be provided to engage the horizontal support surface to prevent the machine and platform from rotating more than a predetermined amount after the roller has engaged the horizontal support surface. Preferably, a handle is also provided near the upper end of the machine to facilitate swinging the machine and subsequent rolling of the machine along the horizontal surface.

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According to another aspect of the invention, a cushioning converting machine is provided for converting sheet-like material into a relatively low-density cushioning packaging product, comprising a forming assembly, which shapes the supply material into a three-dimensional shape, and a feeding assembly for feeding the supply material through the forming assembly, the feeding assembly including a motor, An energy storage device for storing power and a circuit for selectively supplying power from the energy storage device to the motor to energize the motor. In a preferred embodiment, the motor is an electric motor and the energy storage device is a battery carried in a support structure for conformal mounting and the motor. Ideally, the support structure, such as a platform, includes wheels to roll the machine across a floor surface.

The foregoing features and other features of the invention are described more fully below and particularly noted in the claims, the following description and the accompanying drawings set forth in detail in certain illustrative embodiments of the invention; these are

-27Lililí indicators, however, of a few of the various ways in which the principles of the invention can be employed.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a cushioning conversion machine according to the present invention, showing front and rear units thereof, assembled with respect to each other and supported on a table.

Figure 2 is a cross-sectional view, enlarged through the front unit of the machine, taken along line 2-2 of Figure 1 and with one outer cover of the front unit removed.

Figure 3 is an enlarged longitudinal cross-sectional view of the machine, taken along line 3-3 of Figure 1.

Figure 4 is an enlarged cross-sectional view, taken along line 4-4 of Figure 2, showing the position of the internal components of the front unit with its operating handle in a feed position.

Figure 5 is a cross-sectional view similar to Figure 4, showing the position of the

-2828 internal components with the operating handle in a cutting position.

Figure 6 is a cross-sectional view similar to Figure 4, illustrating the removal of a modular cutting assembly 5 as an integral unit.

Figure 7 is a view similar to Figure 2, but with parts removed to illustrate an alternative joining method for the spring deflection elements of the feed assembly/gear joint.

Figure 8 is a cross-sectional view taken along line 8-8 of Figure 7.

Figure 9 is a view similar to Figure 4, alternatively showing that the operating handle can be mounted on the front unit, with the 15^ internal components of the front unit and the operating handle placed in its feed position.

Figure 10 is a cross-sectional view similar to Figure 9, showing the position of the internal components with the operating handle in a cutting position.

Figure 11 is a cross-sectional view taken along line 11-11 of Figure 2.

Figure 12 is a side elevation view taken from line 12-12 of Figure 2.

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Figure 13 is a perspective view, in exploded view of the rear unit of the machine.

Figure 14 is a perspective, exploded view of the outer cover and outlet duct of the front unit of the machine.

Figure 15 is an elevation view showing the converting machine in a vertical orientation, with the front unit supported by a platform and the rear unit supported on a carriage for forward movement and separation from the front unit.

Figure 15A is another elevation view of the conversion machine in Figure 15, viewed from line 15A-15A of Figure 15.

Figure 16 is an elevation view showing the conversion machine in a vertical orientation, with the front unit mounted to a wall and the rear unit supported on a carriage for forward movement and separation from the front unit.

Figure 17 is an elevation view showing the conversion machine in a vertical orientation, with the front unit and rear unit supported on a carriage.

Figure 18 is a perspective view of the other mode of the conversion machine

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cushioning, in which the rear unit is included in a carriage for movement towards and away from the front unit supported on a table.

Figure 19 is a perspective view of another modality of the cushion conversion machine, in which a modified front unit is assembled in an inverted position with respect to the front unit.

Figure 20 is an elevation view showing the conversion machine in a vertical orientation with the front unit and rear units supported by a platform.

Figure 20A is another elevation view of the conversion machine in Figure 20, viewed from line 20-20A of Figure 20.

1^ Figure 21 is a view similar to Figure 2, showing the use of a cover plate to protect electrical components from debris.

Figure 22 is a cross-sectional view taken along line 22-22 of Figure 21, which shows the way in which the cover plate is mounted.

Figure 23 is a cross-sectional view taken along line 23-23 of Figure 21, showing the deck plate in a plan view.

Figure 24 is a longitudinal cross-sectional view through a front-driven unit

-3131 manually, with its operating handle in a neutral position.

Figure 24A is a cross-sectional view through the front unit of Figure 24, taken along line 24A-24A of the same.

Figure 25 is a cross-sectional, longitudinal view similar to Figure 24, showing the operating handle offset to feed the product through the unit.

Figure 26 is a cross-sectional view similar to Figure 24, showing the operating handle shifted forward to cut a cutting section of the packaging product from the strip of the same formed by the cushioning conversion machine.

1^5. Figure 27 is a side elevation view of another embodiment of the cushioning conversion machine according to the invention supported by a platform in a vertical orientation.

Figure 28 is another elevation view of the conversion machine of Figure 27, viewed from line 28-28 of Figure 27.

Figure 29 is a longitudinal sectional view of the converting machine of Figure 27 separated from the platform and taken substantially along line 25 29-29 of Figure 28.

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Figure 29A is an enlarged portion of Figure 29, with part of it in a separate cut to illustrate an adjustment device.

Figure 30 is a longitudinal section view 5 taken substantially along line 30-30 of Figure 29.

Figure 31 is a cross-sectional view taken substantially along line 31-31 of Figure 29.

Figure 32 is an enlarged plan view of the forming member and duct assembly used in the converting machine of Figure 27.

Figure 33 is a side elevation view of the member assembly and forming duct of Figure 32.

Figure 34 is an end view of the member assembly and forming duct of Figure 32.

Figure 35 is a cross-sectional, longitudinal, fragmented view through the machine of Figure 27, showing an interlocking mechanism according to the invention.

Figure 36 is a fragmented, enlarged cross-sectional view taken along line 36-36 of Figure 35.

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Figure 37 is a view similar to Figure 35, but showing the rear unit liner cover removed and the interlocking mechanism uncoupled.

Figure 38 is a view similar to Figure 36 but showing the liner cover removed and the interlocking mechanism uncoupled.

- Figure 39 is a fragmented cross-sectional view of the front unit showing the use of a spring-loaded plunger mechanism according to the invention.

Figure 40 is a fragmented cross-sectional view taken along line 40-40 of Figure 39.

Figure 41 is a plan view of a swing door covering the front unit's outlet opening.

Figure 42 is a cross-sectional view of the door in Figure 41, taken along line 42-42 of the same.

Figure 43 is a side elevation, exploded view of the cushioning conversion machine and support platform of Figure 27, as modified to provide quick manual attachment of the machine to the platform without the need for tools.

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Llllíl

Figure 44 is another exploded elevation view of the modified conversion machine, viewed from line 44-44 of Figure 43.

Figure 45 is another elevation view of the modified platform, viewed from line 45-45 of Figure 43.

Figure 46 is an enlarged bottom plan view of the front unit of the converting machine, viewed from line 46-46 of Figure 43.

Figure 47 is a cross-sectional view, fragmented through the front unit taken along line 47-47.

Figure 48 is a fragmented, enlarged portion of Figure 44.

Figure 49 is a fragmented cross-sectional view taken along line 49-49 of Figure 48.

Figure 50 is an enlarged portion of Figure 45.

Figure 51 is an enlarged portion of Figure 43, partially with a separate cross-section cut.

Figures 52-60 are sequential elevation views showing how the conversion machine is attached to the support platform, with the

-35Lili H ...

Figures 56 and 58, which are enlarged portions of Figures 55 and 57, respectively, and Figures 59A and 60, which are enlarged portions of Figure 59, respectively.

Figure 61 is an elevation, side view 5 showing the converting machine and platform in a horizontal orientation supported butt-on a table with the platform legs replaced by the hanging roller members,

Figure 62 is a fragmented cross-sectional view of another modality of the cushion converting machine, which includes a forming or forming unit and a feeding or head unit, with its parts removed to facilitate the illustration of various modifications of the machine.

Figure 63 is a plan view of the cushioning conversion machine of Figure 62 viewed from line 63-63 and with the covers of the forming and head units removed.

Figure 64 is a side elevation view of the forming unit of the machine in Figure 62, with the cover removed.

Figure 65 is a plan view of the forming unit, the removed cover, viewed from line 65-65 of Figure 64.

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Lilili.

Figure 66 is an end view of the forming unit, the cover removed, viewed from line 66-66 of Figure 65.

Figure 67 is a cross-sectional view of the machine head unit of Figure 62, taken along line 67-67 of Figure 63 and with parts removed for illustrative purposes.

Figure 68 is a cross-sectional view taken substantially along line 68-68 of the

Figure 67.

Figure 69 is a top plan view of the forming unit cover of the machine in Figure 62.

Figure 70 is a side elevation view of the roof of Figure 69 as viewed from line 70-70.

Figure 71 is an end view of the cover of Figure 69 viewed from line 71-71 of Figure 70.

2q Figure 72 is a fragmented cross-sectional view of the head unit of the machine of Figure 62, taken substantially along line 72-72 of Figure 63 and with other parts of the head unit illustrated.

-3737 lililí.

Figure 73 is a fragmented view taken substantially along line 73-73 of Figure 72, with the cut parts separated and shown in cross-section.

Figure 74 is a fragmented cross-sectional view taken substantially along line 74-74 of Figure 73.

Figure 75 is a side elevation view of the machine's operating handle as viewed from line 75-75 of Figure 72.

Figure 76 is a side elevation view showing the machine assembled to a modified platform.

Figure 77 is an elevation view of the platform alone as viewed from line 77-77 of Figure 76.

Figure 78 is a side elevation view of yet another modality of the cushioning conversion machine supported by a platform in a vertical orientation.

Figure 79 is an elevation view of the machine in Figure 78 as seen from line 79-79,

Figure 80 is an elevation view of the machine in Figure 78 as viewed from line 80-80 in Figure 79.

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Figure 81 is a side elevation view of another form of base for the platform shown in Figure 78.

DETAILED DESCRIPTION OF THE INVENTION

Now with reference to the detailed drawings, and initially to Figure 1, a cushioning conversion machine according to the present invention is generally indicated by reference number 20. The machine 20 is shown placed in a horizontal form and loaded with a roll 21 of sheet-like material M. The preferred supply material M consists of two or three overlapping folds or layers of 13.62 kilograms (30 pounds) biodegradable, recyclable, and reusable Kraft paper wound onto a hollow cylindrical tube. Machine 20 converts the supply material into a continuous, unconnected strip of relatively low-density cushioning packaging product 22, which has pillow-like portions 23 separated by a thin center band 24. This strip 22 is cut into sections, or pads, of a desired length for use as protective packaging material. As shown, the machine 20 is compact and can be supported on a table 27 or other platform for the

-3939

UM convenient supply of packaging product cutting sections 22.

Machine 20 is of modular construction including a front or down module, section or unit 30 and a rear or up module, section or unit 31. The front and back references are arbitrary, but are used to facilitate a description of the relative relationship of the machine components. Rear unit 30 and front unit 31 are also referred to herein as the forming unit and the feeding/cutting unit, respectively, in view of the functions described below associated with them. Rear unit 30 and front unit 31 are also referred to herein as the former and the head.

References to "up" and "down" in this document are made in relation to the direction of movement of the supply material M through the machine. It will also be noted that references to "up" and "down," "up" and "down," etc., are made in relation to an illustrated orientation of the machine to describe the positional relationships between machine components and not as a limitation, unless otherwise indicated. The present invention also exemplifies* the various combinations of any feature of the

-4040 lilili.

invention, with one or more other features of the invention, even when shown in separate forms.

The rear unit 31 has a housing in the form of an outer or external box 35. The box 35 has a base 36 and a cover 37 hinged to the base by the hinge 33. The cover can be opened and closed to gain access to the inside of the box, which, in Figure 1, blocks the rear unit components from the inside view. Depending on the base 36 are the 10 laterally separated projections in the form of brackets 38 to support the supply roll. The brackets 38 have at their lower ends grooves 39 for the snug reception of the ends of a supply roll fastener 40 (such as a bar or a fastener as described in the copendant application No. 08/267,960 submitted on June 29, 1994) on which the supply roll is centrally supported for rotation, so that the supply material can be unwound from the supply roll for passage through the machine.

The front unit 30 has a housing 43 that includes an outer or external box 44 and a frame, which is hidden from view in Figure 1 by the box 44 along with other internal components of the front unit.

5 The outer box has a base 4 5 and a cover 46, the

-4141 which are preferably molded from a suitable plastic, for example ABS. Also shown in Figure 1 is an operating lever or handle member 47, which is used to control the operation of the machine, i.e. feeding the supply material through the machine and removing the cut sections from the packaging product.

Figures 2 and 3 show the internal components of units 30 and 31 rear and front.

As will become apparent from the following description, all the active or machined components of the machine are housed in the front unit. As a result, the rear unit is relatively lightweight, although the entire machine is generally relatively lightweight.

1§ is compared with present-day commercial embodiments of the converting machines described in United States Patents Nos. 4,968,291 and 5,123,889. More particularly, such commercial machines weigh more than 181.6 kg (400 lbs) whereas a preferred embodiment of the present invention weighs no more than 45.3 kg (100 lbs) and preferably from about 36.24 kg to 22.65 kg (80 to 50 lbs) and most preferably about 27.18 kg (60 lbs). The preferred illustrated modality adapted to use a 68.58 cm (27 inch) supply material has a length

-4242 total (with the loaded provision roller) of approximately 121.92 cm (48 inches) when compared to approximately 152.4 cm in length of the commercial version of the machine shown in United States Patent No. 5,123,889 (the width and height of this machine are approximately 91.44 cm and 106.68 cm (36 inches and 42 inches) respectively, for a supply material of 76.2 cm wide (30 inches) as well, The rear unit housing has a width of approximately 71.12 cm (28 inches) and a height of approximately 22.86 cm (9 inches), while the front unit housing has a length of approximately 27.94 cm (11 inches), a width of approximately 27.94 cm (15 inches), and a height of approximately 27.78 cm (11 inches). Yet, this compact, lightweight, and portable machine of the invention, It is operable to produce approximately a pad-like packaging product of the same size, approximately 17.78 cm to 22.86 cm (7 to 9 inches) wide and approximately 3.81 cm to 7.62 cm (1 1/2 to 3 inches) thick, as produced by heavier machines, the details of such product and its formation being described in Commonly Assigned United States Patent No. 4,717,613. Also, the preferred packaging product has a density of

-4343 approximately 9.61 to 11.13 grams/liter (approximately 0.6 to 0.7 grams per cubic foot).

As seen on the right in Figure 3, the rear unit 31 includes a preferred inlet guide in the form of an inlet roller 50, which provides a non-variable point of entry for the sheet-like supply material M from the supply roll 21. The supply material passes from the supply roll through an inlet opening 51 in the lower wall 52 of the box base 45. From roller 50, the supply material passes over the separation members, preferably rollers 53-55, which separate the multiple folds P^ - P₃ one from the other before passing over a formation structure 56 and within a conduit of

1. Convergence 57. The preferred provision material L consists of two or three overlapping layers or fabrics of 13.62 kg (30 lb) biodegradable, recyclable, and reusable Kraft paper wound on a hollow cylindrical tube and having a preferred width of 68.58 cm (27 in), 20 although other widths including the standard width of

76.2 cm (30 inches) can be used. A 68.58 cm wide (27-inch) 3-ply roll of 13.62 kg (30 lb) Kraft paper that is 136.8 m (450 ft) long will weigh approximately 14.49 kg (32 lb) and will provide cushioning equal to bags of

-4444 approximately 3 1/2 in a 0.3 cubic meter bag of plastic foam fragment.

The forming frame 56 (as a preferred form of forming member) and the converging conduit 57 function cooperatively and substantially as described in commonly assigned U.S. Patent No. 5,123,889. However, according to the present invention, the converging conduit is preferably formed by a portion of the outer box 35, where the box walls converge toward each other. As best illustrated in Figure 13, the base has a back wall 60 and laterally separated side walls 61. The side walls have parallel back portions 62, converging intermediate portions 63, and converging portions 64, the latter defining an angle smaller than the angle defined by the intermediate portions 59. Cover 37 is configured accordingly and is provided with a rear edge portion 66 and side edge portions 67 that are rotated downwards to engage the rear edges of the base's side and rear walls. As shown, the rear and side edge portions that hang off the cover can be offset outwards at their lower edges to form a peripheral flange 68 that overlaps the upper edge portions of the walls

-4545 rear and side of the base. Here, it can be observed that although the rear and side walls of the box are predominantly formed by the base, as opposed to the cover, more or less of the rear and 5 side walls of the box can be formed by the base, as desired. That is, the dividing line between the base and the cover can be located in any other way, such as along a median plane through the box, although preferably the dividing line is placed above the median plane.

Before leaving Figure 13, note that the forming frame 56 is secured and held in place by the cover 37. This feature of the invention facilitates the initial feeding of the supply material 1? M through the machine. The conventional practice is to fold triangular portions of the front end portion of the provisioning material together to form an arrow shape that is fed under the forming frame before it passes to a feeding mechanism.

0 With the forming frame carried by the cover, it is moved out of the way when the cover is opened. This provides convenient access to the inside of the box to fold the front end portion of the provisioning material into a narrow shape and advance the provisioning material forward.

-4646 coupling by the feeding mechanism. As shown, the forming frame has the centers of the transverse members secured to the same vertical posts 71 and 72 that are joined at their upper ends 5 to the deck. For further details of the forming frame and its function, reference may be made to United States Patents Nos. 4,717,613 and 4,750,896 commonly assigned. Furthermore, according to the present invention, the forming frame can be formed integrally with the duct, i.e., as part of a single plastic molding and preferably the cover.

Figure 13 also shows how the input roller 50 and the separation rollers 53-55 are supported by and extended between the rear portions 1L 62 of the side walls 61 of the base 36 or, more generally, the housing 31, so that the housing also functions as an external frame for the separation rollers. The rollers can be of any suitable type and properly driven for rotation. For example, the 20 rollers may include outer roller sleeves, which rotate on shafts extending through them, with the ends of the shafts secured to the side walls of the housing. The lowest roller is preferably of a larger diameter than the two upper rollers.

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Lilili...

It can also be seen in Figure 13 that the front ends of the base and cover have outward-extending flanges 73 and 74, respectively, which are coplanar and together form a projection surrounding an outlet opening 75 through which the supply material M passes from the rear unit to the front unit.

Again, with reference to Figures 2 and 3 and additionally with Figures 11 and 12, the front unit 30 includes a frame 79 to which a feeding/sewing mechanism 80 and a cutting mechanism 81 are mounted. The feeding/sewing mechanism 80 comprises gear-like members 83 and 84, generally loosely interlocked, rotatable, which are adapted to join the supply material along the central band 24 (Figure 1) to sew the supply material together, thus maintaining the three-dimensional shape illustrated in Figure 1. Gear-like and rotating members mesh with and move the product through the machine, pulling the feed material onto the forming frame and discharging the product through an outlet opening 86. An electric motor 87 and a speed reducer 88 are used to drive the gear-like member 83, which, due to the generally interlocking relationship between the

-4848 gear-like members, drives the other gear-like member 84. The gear-like members are preferably of the type described in United States Patent No. 4,968,291 commonly assigned, whose gear-like members or gears function to pierce the center band.

The gear-like member 83 is fixed to the drive shaft 90 which is rotatably mounted by the cushions 89, secured to the respective frame members 91 and 92 of frame 79, whose members are in the form of plates that are joined together in laterally separated relation by a lateral frame or plate member 94 extending transversely. A sprocket 93 is secured to one end of the drive shaft laterally outward from the relatively adjacent frame member 92. The sprocket 93 is connected by an endless chain 95 (or belt or other suitable means) to a drive sprocket 96 secured to the output shaft of the speed reducer 88, which is driven by the electric motor 87. The speed reducer and electric motor are mounted to, and inside, the relatively adjacent frame member 92. Although this arrangement is advantageous, other suitable means may be employed to rotately drive member 83.

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Lilili....

similar to a gear and such other means form a part of this description of the invention.

The gear-like member 84 is supported for rotation on a shaft 98 arranged with its ends 5 guided in slots 99 in frame members 91 and 92. The ends of shaft 98 are spring-loaded by spring-deflection assemblies 102 that are operative to push shaft 98 and the gear-like member 84 carried on them, towards the other shaft 90 and the gear-like member 83 that moves resiliently to maintain the gear-like members in interlocking relation with the provision material between them. As best shown in Figure 4, each spring deflection assembly 102 includes a tie-down member 103 that extends transversely with respect to the shaft axis 98 and, more particularly, passes diametrically through an opening 104 in the tie-down member 103. The tie-down member has an enlarged head 105 at one end thereof, and is therefore anchored to a fixed support 107. The support 107 is mounted to the transverse frame member 94. Screwed into the end of the tie-down member opposite the support 107, there is an adjustable retainer 110 and supported on the tie-down member between the support 107 and the adjustable retainer 110 is a helical spring 111.

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Therefore, shaft 98 is free to float, i.e., move toward and away from shaft 90, to accommodate different thicknesses of provision material between the gear-like members, while the five springs 111 of the deflection assemblies 102 provide clamping pressure to achieve the desired seam or joint action. The clamping pressure can be varied by adjusting the position of the retainer 110 along the length of the clamping member. This can be easily accomplished by rotating the clamping member 103, thereby advancing or retracting the retainer 110, noting that rotation of the retainer is prevented by interference with the cross-frame member 94. Also, the head of the clamping members may be slotted or configured in any other way to facilitate turning by using a screwdriver, wrench, or other suitable tool. As desired, the retainer can be adjusted to preload shaft 98.

0 As best shown in Figure 2, the upper portion of the cross-frame member 94 has several cutouts to accommodate other front unit components, while providing a protrusion for the supports 107. In an alternative arrangement shown in Figures 7 and 8, the cross-frame member 94

-5151 can be replaced by a simpler rectangular prime plate 94 and the laterally separated supports 107 (which in the illustrated embodiment are in the form of L-shaped brackets or lugs) can be mounted to the side frame members 91 and 92. This results in less cost and weight.

The feeding/sewing mechanism 80 shown in Figure 2 performs dual functions in the operation of machine 20. One function is a pulling function in which stock material is drawn out, through the clamping point of the two cooperating and opposing gear-like members. Thus, the feeding/stitching mechanism is the mechanism that pulls the stock material from the stock roll 21, through the assembly fold that separates the rolls and through the forming assembly comprising the forming frame and the converging conduit 57. The forming assembly 52 causes the inward rolling of the side edges of the sheet-like provisioning material 22 to form the pillow-like, side portions of the continuous strip l.

The second function performed by the feeding/sewing mechanism is a sewing or joining function, so the folded-over edge portions of the provision material are connected to each other/to the region

-5252 unfolded central strip of the supply material. Specifically, the strip is connected by two opposing gears that join (and preferably also pierce) its central band passing through them to form the joined strip 22 (Figure 1). As the joined strip 22 moves down the interlocking gears, the strip is guided through and laterally restrained by a tubular guide or guide duct 114. As shown in Figures 2-4, the guide duct is rectangular in cross-section, and its upper and lower walls have outwardly flared edge portions at the duct's inlet end. The duct forms part of the cutting mechanism that cuts the strip into sections.

1¿ With reference now to Figures 2, 4 and 5, the cutting mechanism 81 includes a blade assembly 119 comprising a pair of relatively movable blades 12 0 and 121, which are mounted on a guide structure 122 to which the guide conduit 114 is preferably attached 2 0 by a bracket 123. The guide frame 122 includes upper and lower frame members 125 and 126 that are interconnected by a pair of laterally spaced guide rods or posts 127, which extend between the upper and lower frame members. The upper and lower frame members 25 are adapted to be

-5353 lil lí secured at their ends to the side frame members 91 and 92 by suitable means, such as removable screws received in threaded holes 129 at the ends of the upper and lower frame members. When assembled in that way to the side frame members, the upper and lower frame members serve to reinforce or stiffen the main frame 79 of the front unit 30, although it is easily removed from there for the reasons discussed below.

In the preferred embodiment illustrated, the blade 120 is a stationary blade fixed to the lower frame member 122 above a spacer 131. The other blade 121 is a moving blade mounted on a carriage 133, which may be of the split-wedge type illustrated, to allow fine adjustment of the moving blade relative to the stationary blade. The blade carriage 133 has at its opposite ends guide bushings 13 5, which slide on the guide posts 127 for movement perpendicular to the axis of the guide channel 114. Consequently, the blades, when they come together, act in a guillotine-like fashion to cut the joined strip 22 (Figure 1) into cutting sections.

The stationary blade 120 is mounted on the underside of the guide duct 114, while the

-5454 Blade 121 is movable between a feed position shown in Figure 4 and a cut position shown in Figure 5. In the feed position, the moving blade is located above and away from the outlet opening of the guide duct 114. From the feed position, the moving blade moves down to the cutting position, passing through the outlet opening of the guide chute and co-acting with the stationary blade to cut the attached strip located between the blades. Preferably, the stationary blade is positioned close to the lower side of the outlet opening of guide duct 114 and thus extends mostly below the duct except for its cutting edge which projects slightly beyond the lower edge of the duct.

The moving blade 121 is operated by an operator assembly 140. The operator assembly includes a U-shaped handle member 141 having mounting blocks 142 at the ends of its legs, secured to the outer ends of the respective crankshafts 143. The crankshafts pass through and are rotatably supported by the side frame members 91 and 92, respectively. The inner end of each crankshaft has a slotted crank 144 secured to it, also referred to here as a lifting lever. As discussed

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Ullli further states that the handle can be connected to the crankshafts in a plurality of angular relationships to the crankshafts.

Each slotted crank 144 has a slot 141 5 extending radially with respect to the axis of rotation of the crankshaft. The slot 155 is adapted to receive a cam pin 146 provided at the corresponding end of the moving knife-edge carriage 133 as shown in Figures 2, 3, and 4. In a well-known manner, the slotted crank cooperates with the cam pin to transfer the rotary motion of the crank to the linear motion of the knife carriage. The movement of the handle member 141 between its positions, as shown in Figures 4 and 5, will effect the corresponding movement 15^ of the moving knife between its feed and cutting positions.

It is observed that the crankshafts lie in a plane that is perpendicular to the cutting plane of the blades and which intersects the intermediate cutting plane of the 20-stroke moving blade. More specifically, the plane of the crankshafts is located in the middle of the guide channel. Therefore, during the end portion (preferably about the last half) of the cutting stroke of the moving blade, the rear side 25 of the grooves in the cranks not only

-5656 will exert a downward force on the cam pins (and thus on the moving blade) in Figures 4 and 5, but also a horizontal force that pushes the moving blade against the stationary blade to ensure a clean cut. Preferably, the moving blade has passed over the center at the time when the packaging product has been compressed between the blades to initiate a cut in such a way that during the cut the moving blade will be held tightly against the stationary blade as it passes over it. Furthermore, this clamping force will progressively increase as the moving blade completes the cutting stroke, since the angle between the plane of motion of the moving blade and the back side of the crank slots progressively increases during the final portion of the cutting stroke.

As shown in Figures 4 and 5, the groove 145 is open at one end. This is important for one of the advantages of the present invention. More particularly, the open-ended groove allows the cam pin to be disengaged from the grooved crank without having to disassemble any element of its support structure. As illustrated in Figure 6, this facilitates the easy removal of the blade assembly 119 as a unit.

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The LUDJ integral of the main frame of the front unit is removed by removing the retaining screws that secure the upper and lower guide frame members to the side frame members of the main frame. Easy blade removal is advantageous because it allows for quick replacement of the blade assembly with another assembly, such as for repair or sharpening of the blade assembly. This is particularly beneficial when servicing the machine in the field.

With further reference to Figures 4 and 5, a switch 150 is mounted to the frame member 91 with its displacing lever located in the path of the crank 144 relatively adjacent to it. The switch is actuated by displacing the slotted crank to its feed position, which corresponds to the feed position of the handle. When the switch is activated, the feed motor 87 is energized to rotate the gear-like members for feeding the supply material through the machine with the packaging product being advanced through the guide chute 114. Therefore, the handle can be moved clockwise to its position illustrated in Figure 4 to activate the switch and energize the feed motor to advance a length of the

-5858 l111,1 packaging product through the guide channel until a desired length of product has been displaced. The handle can then be moved in the opposite direction, counterclockwise in Figures 3 and 4, to its cutting position shown in Figure 4 to cut a piece of the packaging product to the desired length. The handle can be raised in the position shown in Figure 4 until the next piece of packaging product is needed, at which time the handle can be moved to its feed position to displace a desired length of packaging product. In a known form, a master on/off switch can be provided to control the supply of electrical power to the motor and switch. A reverse switch may also be provided to operate gear-like members in reverse to assist in clearing a jam in the machine.

The product fed through guide chute 114 passes into outlet chute 156, shown in Figure 3. Outlet chute 156 is axially aligned with guide chute 114 below the cutting plane defined by the path of movement of the moving blade 114. The outlet chute has a flared, funnel-shaped portion 158.

-5959 outward tapering into a rectangular portion 159 downward. The inlet portion has an orifice larger in size than the cross-sectional area of ​​the guide conduit, while the downward portion has essentially the same cross-sectional shape as the guide. The flared hole functions to receive and guide into the outlet duct the freshly cut leading end of the strip after a piece has been cut, whose new leading end may have been pushed 10 off-axis by the cutting operation and remains off-axis. As shown in Figure 3, the lower edge of the hole is below the plane of the lower frame member 126, the latter preventing the strip from being displaced downwards, so that it will not be captured 15 by the outlet duct hole. Ί

As shown in Figures 13 and 14, the outlet duct 156 is located between the cover 46 and the base 45 of the external housing 44, which encloses the internal components of the front unit. The operating handle is located externally to the housing 44 for manipulation by an operator as described above. The crankshafts to which the handle ends are mounted extend through the 162 openings formed by slots provided in the 25 dividing line of the case cover and base.

-6060 cover may have an offset peripheral flange, overlapping the upper edge portion of the base in a manner similar to that described above with respect to cover 37 and base 36.

As shown in Figure 14, the case is generally rectangular in shape, with one side having a triangular protective portion 164 facing outwards to house the drive chain and sprockets. Preferably, the cover and base 10 are molded from a suitable plastic, for example ABS, since the outlet chute may be trapped between parts of the case or secured to any of the parts of the case. The parts of the box, in turn, are secured by fastening means suitable to the frame of the front unit.

Now with reference to Figures 9 and 10, the handle 141 is shown secured to the crankshafts 144 at a different angular relationship, as is advantageous to provide flexibility of use of the machine in 20 different arrangements as will become more apparent from the following discussion of Figures 15-19. In Figures 9 and 10, the handle is secured in a position rotated 90° from that illustrated in Figures 4 and 5. These place the handle for manipulating the base or 25 lower side of the first unit and, conversely, the

-6161 Cover or top side of the base unit. Any suitable means may be provided for mounting the handle blocks to the crankshafts in a plurality of different, relatively rotated positions.

Now, with reference to Figures 15-19, several alternative arrangements or methods of using the converting machine 20 are illustrated. These figures illustrate the flexibility of use provided by the supply of modular front and rear units that can be interconnected in various ways, such as vertically, horizontally, or inverted relative to each other. Arrangements other than those illustrated may also be used. For example, the rear and front units can have their axes oriented either horizontally or vertically, or the rear and front units can be arranged in a coplanar relationship such as at an angle, for example 90°, while the outlet opening of the rear unit and the inlet opening of the front unit cooperate to provide a path for the supply material between them. In the case of such an angled placement, preferably a guide path such as a rounded elbow is provided between the outlet and inlet openings.

In Figures 15 and 15A, the rear and front units are oriented vertically with the unit

-6262 front unit 30 supported on a platform 167 and the rear unit 31 supported on a carriage 168 having a frame 169 and wheels 170 such as furniture casters for swiveling on a floor. The platform 167 includes on each side of the front unit an identical mounting of a base 162 and a vertical 173. The front unit is secured between the upper ends of the uprights by brackets 174 or other suitable joining hardware, with its lower portion positioned slightly above the top of the rear unit. The uprights have their lower end portions curved outward to accommodate (mount) the rear unit 31, which can be rolled under the front unit to align with the outlet opening of the JL5. The rear unit has an inlet opening for the front unit to allow the upward passage of supply material from the rear unit to the front unit. As shown, handle 47 is mounted in its position illustrated in greater detail in Figures 9 and 10.

The rear unit 31 can be mounted at its rear end to the carriage frame 169 with the roll support projections 33 reversed from their position shown in Figure 1 to receive a roll of supply material from above. Of course, the roll support projection 25 is positioned above the

-6363 carriage frame a sufficient distance to avoid interference between the supply roller and the frame. If desired, the upper unit may have attached to its sides, depending on the guide elements 176, which can couple and guide the projection 177 of the rear unit in the appropriate positional relationship with the front unit and then further assist in maintaining the rear unit in such position during machine use.

The ability to move the carriage in and out of relation to the front unit, as illustrated by arrows 178, has several advantages, such as providing remote loading of a supply roll onto the rear unit, which can then be moved into position. If desired, more than one rear unit and carriage assembly can be provided, so that one can be in use while the other is being loaded with a new supply roll.

In Figure 16, the front unit 30 is shown mounted to a wall 180 or other vertical surface. The front unit is attached to the wall by mounting brackets 181 or other suitable joining hardware at a height located at the bottom of the front unit slightly above the rear unit 31, which is supported on a carriage 168 as described above in relation to Figure 15.

-64£1114;

Likewise, the rear unit can be moved under the upper unit in a similar manner.

In Figure 17, the rear and front units are both supported in a vertical orientation by securing to a vertical support 185, which in turn is supported on a cart 186 for transporting the machine from one location of use to another or between positions of use and storage. The vertical support may be in the form of a frame having vertical posts 187 interconnected at their upper ends by a cross-frame member and braced at their lower ends by corner brackets 188 onto the carriage. The carriage is supported by wheels 188 such as small casters for rolling on a floor.

In Figure 18, the rear and front units are oriented horizontally with the front unit 30 supported on the top 191 of a table and the rear unit 31 supported on a cart 192 having a frame 193 and wheels 194 such as small casters for turning on the floor. The rear unit's outlet opening and the front unit's inlet opening are at the same height, so the rear unit can be moved to the position shown by aligning the outlet and inlet openings. The use of this arrangement is substantially the

-6565 same as that described above with respect to Figures 15 and 16, except for the orientation of the machine.

In Figure 19, the rear and front units are assembled together in the same way as shown in Figure 1, except that the rear member 31' is in an inverted position. For use in this arrangement, the rear unit has a hinged door 196 at its base, which functions as the cover of the configuration shown in Figure 1 to allow access to the interior of the rear unit for initial threading of the supply material through it. A modified form of the supply roll protrusion 38' is also provided to support the supply roll above the rear unit. As shown, the rear unit is supported on spacers to raise its outlet opening to the same height as the inlet opening of the front unit.

In Figures 20 and 201, the front and rear units 30 and 31 are both supported in a vertical orientation by being secured to a vertical support 200 in the form of a bent tubular frame, which can be formed, as illustrated, by selecting a single length of pipe and the like. As shown, the upper portion of the support generally has an inverted U-shape, having a pair of legs 201 and a portion 202

-6666 of connection cove. The legs 201 are generally coplanar and diverge from each other going from top to bottom. Each leg terminates in a base 203 which extends out of the plane of the legs 201 in a first direction and then back upon itself in the opposite direction through and beyond the plane of the legs, to provide together with the lateral separation of the legs, a wide support base for the vertical or standard support 200. The raised portion of the base, which terminates at the lower end of the respective leg, may be fitted with a suitable support to receive and support the ends of a roll holder 205 that supports the supply roll 21. Viewed in another way, the legs are generally J-shaped with the stem oriented to be placed on a floor and the hook of the J attached at its distal end to the lower end of the corresponding leg. If desired, the standard can be equipped with wheels such as small casters for rolling on a floor.

Now with reference to Figures 21-23, a cover plate 210 is provided to protect the motor 87 and any associated electrical components from debris falling upon them, such as particles or pieces of paper that must be generated as a result of the paper being formed, joined, and cut into shape

-6767 described above. The cover plate 210 has upwardly flexed lugs 211 at its opposite ends for fastening by fasteners 212 to the edge of the lower frame member 126. As best seen in Figures 22 and 23, the cover plate 210 has a rearward-extending tongue portion, which extends underneath and engages the lower side of the lower frame member 126. As also shown, the lower frame member 126 has a separate forward-facing shear opening, which is expanded and thus closed by the rearward-extending tongue portion 214 of the cover. The cover also has a portion 216 that extends forward from the mounting lugs 211 a distance sufficient to close the gap between the lower frame member 126 and the front wall of the housing 43. The cover plate 210 also extends transversely between the side frame members 91 and 92. In this way, the opening defined by the side members 91 and 92, the front wall 217 of the housing 43, and the lower frame member 126 is substantially closed to prevent particles or pieces of paper from falling from the paper path down onto the motor 87.

With reference now to Figures 24 and 24A, the relevant internal components of a

-6868 Front unit 231 manually operated. Front unit 281 is similar to front unit 30 except for the way in which the feed/sewing mechanism and the cutting mechanism are operated. As will be noted, these mechanisms are manually operated, which eliminates the motor 87 and associated drive components of unit 30, or other driven devices such as a fluid motor and associated drive components. This results in a substantially lighter front unit, since the front unit 30, motor 87, and speed reducer 88 account for a significant portion of the front unit's weight. It also eliminates the need for an electrical power source.

As mentioned above, front unit 231 is similar to unit 30 described above, and therefore, reference may be made to the above description of front unit 30 for details of front unit 231 that will not be described or shown below in Figures 24 and 24A.

Like front unit 30, front unit 231 includes a frame 233 to which a feeding/sewing mechanism 234 and a cutting mechanism 235 are mounted. The cutting mechanism 235 is essentially identical to the cutting mechanism 81 described above for front unit 30, although it can be seen in Figure 24 that its

-6969

HUI.....

The positional relationship with respect to frame 233 has been varied, while its positional relationship to the gear-like members 237 and 238 of the feeding/sewing mechanism 234 has been maintained. Note that in Figure 24, the protective material passes from left to right.

As in unit 30, the gear-like members are generally loosely interlocked and operational to couple and move the product through the machine, pulling the provision material over the forming frame upwards and discharging the product out through an outlet opening provided in the outer housing or casing of the front unit, in the same manner described above in relation to front unit 30. The gear-like members 237 and 238, however, are rotatably driven in a different manner than that described above in relation to the front unit 30. The gear-like member 238 is fixed to a drive shaft 20 240, which is rotatably mounted by suitable bearings in the frame 233. A gear 242 is connected by a one-way clutch device 243, internal to one end of the drive shaft 240 that projects laterally outward from the relatively adjacent side frame member 244 of the frame 233.

-7070 lll 1 gear 242 is intermittently coupled by a segment gear 246 that is keyed to a relatively adjacent one of the crankshafts 247, to which the opposite ends of the shank member 249 are attached in their mounting blocks 250. As in the front unit 30, each crankshaft 247 passes through and is rotatably supported by the relatively adjacent side frame member 244. Also, the inner end of each crankshaft has a grooved crank 253 secured to it.

The gear-like member 237 is supported for rotation on a shaft 255 arranged with each end thereof guided by the screw of a respective spring deflection assembly. Each spring deflection assembly 258 is identical to the spring deflection assembly 102 described above, except that the fixed bracket 259 can be conveniently mounted to the relatively adjacent transverse frame member 261 and the adjustable retainer 260 is restricted to vertical movement only by a screw passing through a vertically elongated hole in the transverse frame member 261. Shaft 255 is thus free to float, i.e., to move towards and away from shaft 240, to accommodate different thicknesses of provision material between the gear-like members,

-7171 ¿jíü ι;

while the spring 262 of each diverter assembly provides clamping pressure to achieve the desired stitching and joining action. The clamping pressure can be varied by adjusting the retainer 260. The ends of shaft 255 terminate close to the plane of motion of the respective slotted cranks 253, so that the slotted cranks can be swung to pass shaft 240 to provide a greater range of swung motion for feeding the supply material.

The gear-like member 237 rotates when the gear-like member 238 is rotated. The rotation of the gear-like member 238 is effected by moving the handle 249 from its position shown in Figure 24 to its full feed position shown in Figure 25. Segment gear 246 has a toothed segment 263 meshing with gear 242, so gear 23 8 is rotated counterclockwise in Figures 24 and 25 as the handle is moved counterclockwise from its neutral position shown in Figure 24 to its full feed position shown in Figure 25. This clockwise rotation of gear 242 is transmitted through the one-way clutch 243 to the shaft 248 to rotate the similar member 238

-7272 to a gear in a counterclockwise direction in Figures 24 and 25. Such clockwise rotation of gear-like member 238, which corresponds to the counterclockwise rotation of gear-like member 237, will feed the product from left to right in Figures 24 and 25.

During the return movement of the full-feed exposure handle in Figure 25 to its neutral position in Figure 24, the gear-like members 237 and 238 will not be rotationally driven. Instead, a one-way clutch will allow gear 242 to be rotated counterclockwise without any rotational movement being imparted to shaft 240. Therefore, handle 249 can be rotated back and forth between its neutral position in Figure 24 and its full feed position in Figure 25 to feed product from left to right in Figures 24

0 and 2.5, the supply material that is pulled onto the forming frame in the rear unit and the product that is discharged out through the outlet opening of the front unit. As will be seen, the U-shaped handle member 249 can be conveniently held in its base position extending transversely between

-7373 .111 ι.

The legs of the handle are manually pushed and pulled back and forth to feed paper through the machine. The handle 249 is also used to operate the cutting mechanism 235 in a manner similar to that described above in relation to the front unit 30. As noted above, each crankshaft has a slotted crank 253 secured to it for common rotation. The slotted crank 253 has a groove 265 adapted to receive the cam pin 266 10 provided in the carriage 267 of the moving blade.

The slotted crank cooperates with the cam pin to transfer rotary motion from the crank to the linear motion of the blade carriage 267, which is guided by the guide rods 268. The blade carriage, guide rods, and other components of the blade assembly 270 are essentially identical to the corresponding components described above in relation to the blade assembly 119.

The slotted crank 253, however, differs slightly in that the side wall 272 of the slot that engages the cam pin during the return stroke of the moving blade is radially sized to release and thus clear the cam pin after the movement of the blade carriage 267, which has been fully retracted to its position shown in Figure 24.

-7474

Uill 4.

(Therefore, opposite sides of the groove have different radial lengths.) This allows the grooved crank to rotate from its position shown in Figure 24 to its position shown in Figure 25 during the feeding of the product through the converting machine. After a desired length of product has been produced by the back-and-forth movement of the handle, between its neutral and full-feed positions as described above, the handle 10 can be rotated from its neutral position shown in Figure 24 to its full-cut position shown in Figure 26 to cut a strip of the product, the cutting action which is essentially the same as that described above in relation to the cutting assembly of the JA front unit 10.

As shown, the segment gear 24 6 has a toothless segment 274, which passes over the teeth of gear 242 when the handle is rotated from its neutral position shown in Figure 24 to its full cut position shown in Figure 26. Consequently, each rotation of the handle will not impart rotation to gear 24 2, so that the product will not be fed through the machine during the cutting operation.

In view of the above, it can now be seen that a product feeding mechanism is provided.

-7575 simple, relatively lightweight, which can be used in place of the motor-driven feed mechanism of the front unit 30. This is particularly advantageous in situations where users have 5 relatively low volume requirements, so that manual operation of the handle 24 9 will not be an overload placed on the user. A machine equipped with the manually operated front unit 231 is particularly useful for more portable applications where electrical power 10 is not available, such as on the back of a moving blade.

Now with reference to Figures 27 and 28, another embodiment of the cushioning converting machine according to the present invention is generally indicated by reference number 300. Machine 300 is for the most part the same as machine 20 described above except for the provision of a forming duct and a forming member assembly generally indicated by 302 in Figure 29. In addition, there are 20 other minor differences, which will be described below. For any other details of machine 300 not described or mentioned below, reference may be made to the description of machine 20.

-7676 lili I,

Accordingly, machine 300 comprises a front unit 304 and a rear unit 305. The front and rear units are supported in a vertical orientation by a platform 306. In this orientation, the front unit may be referred to as an upper unit and the rear unit as a lower unit.

The platform 306 comprises an upper vertical position 307 and a lower base portion formed by a pair of legs 308 configured for stable support 10 above a horizontal surface such as the floor surface. The upper portion 307 is inverted U-shaped and has a pair of legs 309 extending downward from a base portion or cove 310. The front unit 304 is secured to the upper portion 307 at the base portion 310, which has a width dimension generally corresponding to, but preferably slightly less than, the width dimension of the front unit 304. From the cove portion 310, the hanging legs 309 diverge, separating from each other at approximately the width of the rearmost portion 20 of the rear unit 305, where the legs terminate in parallel end or post portions 311. The lower end portions of the legs are interconnected by a transversely extending frame member 312 to which the rear unit 305 25 is secured by suitable fastening means.

-7777

HUI..

The lower, parallel end portions 310 of the upper frame legs are telescoped into respective tubes 315 formed integrally in the legs 308. The end portions of the legs may be fixed to suitable middle tubes such as by welding or may be inserted with a sliding fit so that the upper frame may be conveniently separated from the legs and, if desired, supported on a horizontal surface for use of the machine in a horizontal orientation, together with a carriage which positions the paper for proper entry into the rear unit 305. As shown in Figure 28, the rear unit has an inlet opening in its base wall for the passage of the supply material into the rear unit. Each leg includes a respective support for a pair of 316 brackets to receive the ends of a supply roller clamp.

As will be seen, the legs can be removed from the upper frame portion to provide a more compact arrangement for shipping. Each leg 308 includes the vertical tube 315 and a J-shaped member 317. The vertical tube is connected from a point midway between the ends of the longer leg of the J and the end of the shorter leg of the J at a point

-7878

Jll L approximately in the middle along the length of the vertical tube. The J-shaped portion can be bent from a single piece of pipe or similar material. The lower or longer leg of the J-shaped member projects forward and backward from the vertical tube sufficiently to provide stable support for the 300 machine. If desired, each leg can be fitted with casters, such as small furniture casters, for rolling on a floor.

Now with reference to Figure 29, front and rear units 304 and 305 are shown with their internal components removed except for the forming duct and forming member assembly 302. In addition to the forming duct and forming member assembly 302, which is installed in place of the forming frame 56 of machine 20, the other internal components of front and rear units 304 and 305 are the same as those described above in relation to machine 20 and may be referenced therein for details not discussed below. However, the outer 320 and 321 boxes of the front and rear units respectively differ in a few aspects.

The front unit 304's outer 320 box is provided with a one-way flap door 323, which

-7979

JIE 1..

It covers the outlet opening of the front unit. As shown further in Figures 41 and 42, the flap door 323 is mounted by a joint 325 to the front end wall of the outer box 320, such that when in the closed position the flap door expands and thus closes the exit opening 322 to prevent foreign objects from entering through the opening 322 and interfering with the cutting mechanism located immediately inside the opening 322. The hinge 10 may be a spring-loaded mechanism or another means may be provided to deflect the door 323 to its closed position illustrated in Figures 29, 41, and 42. Alternatively, gravity may be relied upon to move the door to a closed position. Of course, the door will be pushed open as the product advances through the exit opening 322.

Again with reference to Figure 29, the cover 330 of the rear unit's housing 321 is not hinged to the housing base 31 as was the case in machine 20. Instead, the cover is removably attached to the base by one or more hinges 333. As shown in Figure 29, the base may have slotted cavities 334 to accommodate the portion of the hinge attached to the base 331. As also shown in Figure 29, the lateral and posterior border portions

-8080 .111 I.

that hang from the cover can be displaced outwards at their lower edges to form a peripheral flange 336 that overlaps the upper edge portions of the rear and side walls of the base 331. Also, 5 the dividing plane between the cover and the base can be parallel to the upper surface of the cover, which, if desired, can have flanges formed thereon that extend longitudinally into grooves to add rigidity to the cover.

As further shown in Figure 29, the lower wall 337 of the base 331 may have a metal plate 338 or another stiffening member secured to it. The stiffening member 338 preferably overlaps the cross-frame member 312 of the vertical portion 306 to provide better securing of the unit to the cross-member when fasteners such as screws, bolts, or nuts are used. The metal plate is also used on machine 20 to provide a stronger mounting structure for attaching the supply roll support brackets 38. Of course, it will be appreciated that machine 300 can be supported horizontally on a table in the same manner illustrated in Figure 1 in relation to machine 20, or the machine can be mounted in any other way on a

-8181 diversity of forms a few of which have been illustrated in Figures 15 to 20.

As shown in Figure 29, the forming duct and forming member assembly 302 comprises a longitudinally converging member or duct 350 and a forming member 351. In the converting machine 20, the forming duct is formed by the converging side walls of the outer housing 331 of the rear unit 305. However, it may be advantageous for manufacturing purposes to form the forming duct as a separate piece assembled inside the outer casing of the rear unit. The funnel-shaped forming conduit can be formed from any suitable material, such as, for example, a plastic which is preferably transparent to facilitate observation of the product, as should be advantageous when the cover is removed to screw the supply material through the machine for ignition.

With reference to Figures 29 to 34, the forming duct 350 has a mounting plate 354 secured to its lower wall, which has a flared rear end portion extending axially to the rear of the duct for convenient attachment to the lower wall portion 355,

-8282 ¿4114 inclined of the base of the rear unit box. Suitable fastening means, such as bolts and screws, can be passed through the holes at the rear end position of the mounting plate 5 354 to fix the forming duct in position within the tapered portion of the rear unit housing just above the rear unit outlet end, which is located immediately above the feed/stitching mechanism (not shown) 10 on the front unit 3 04. Although the feeding/sewing mechanism is not illustrated in Figures 29 and 30, the relationship between the output end of the rear unit and the internal components of the front unit is clearly illustrated in relation to Machine 20 described above.

The conduit 350 comprises an inlet opening 358, generally in the shape of an enlarged O, formed or defined by the rear edges of the generally flat upper and lower walls 359 and 360, and arched side walls 361. The upper wall is generally trapezoidal in shape, while the lower wall is generally rectangular, with these walls converging towards each other to define the outlet opening 363 of the outlet conduit.

The 365 outlet opening is generally configured

-8383 luí a.

semi-oval in elevation as shown in Figure 34, the oval half being taken along the major axis as opposed to the minor axis of the oval.

As the sheet-like material is passed through the forming duct 35 0, the side edges of the provision are rolled inwards and generally in a spiral shape and are pushed inwards towards another, such that the inwardly rolled edges form pillow-like portions, Elastic supply material placed in lateral butt contact as it exits the outlet end of the forming channel and adapted to be joined together by the feeding/stitching mechanism. The forming channel can be formed from any suitable material and can be conveniently formed from a suitable plastic material such as fiberglass.

The forming member 355 works in conjunction with the forming chute 350 to ensure proper paper forming and shaping. The forming member guides the central portion of the provision material along the lower wall of the forming chute 360 ​​for controlled inward winding of the side edge portions of the provision material. The forming member projects rearward.

-8484 of the forming chute inlet to properly guide the provisioning material into the forming chute. The forming member also extends into the forming chute with its forward end 5 positioned relatively close to the bottom wall below the forming product adjacent to the forming chute outlet.

The 351 formation member has a perforated U-shape, generally resembling a fork. The cove or base portion 370 of the formation member is rounded and preferably semicircular. The preferred forming member is made of a suitable material such as plastic, which has sufficient flexibility so that the rounded cove portion HL of the forming member functions as an active joint allowing adjustment of its lower leg 372 towards and away from the lower wall 360 of the forming channel, as further discussed below.

The legs of the U-shaped forming member are generally straight and converge toward each other to give the U its perforated or forked shape. The upper leg 374 is attached to the upper wall 359 of the forming duct along the central plane of the duct by suitable fastening means such as rivets.

-8585 .111 I ,.

Screws, bolts, cement or other adhesive and the like. The upper leg can be flexed, for example, at the outlet end of the forming chute to displace the cove portion of the U downwards to provide a desired gap between the rear end of the forming member and the lower wall of the box base to properly guide the separated folds of the sheet material into the inlet end of the forming chute.

The lower leg 372 of the forming member 351 generally extends parallel to the lower wall 360 of the forming duct and consequently to the sloping wall portion 355 of the lower wall of the base of the box 331. However, the relative inclination and separation between the lower leg of the forming member and the lower wall of the forming duct can be adjusted as needed to obtain proper shaping and forming of the lateral edges of the provision material in the pillow-like portions.

0 Relatively low density, with the inner edges overlapping for connection by the feeding/sewing mechanism in the front unit. Such an adjustment can be effected and then maintained by an adjustment device 377, which, as shown in Figure 29A, extends between the legs of the forming member in a

-8686 point in the middle part along the length of the lower leg, noting that the upper leg may be shorter only by a length sufficient as required to provide attachment to the upper wall 5 of the forming duct. The adjustment device in the illustrated form consists of a threaded screw 378 having a bent lower end threaded into a threaded hole in the lower leg 372 of the forming member and held in place by a retaining nut 10. The upper end of the adjusting rod extends through a hole in the upper wall of the forming duct as well as through a hole in the upper leg of the forming member and is held in place by opposing adjusting nuts 3 79 and 3 80 threaded into the rod on opposite sides of the upper wall of the forming duct. The nuts can be loosened, the rod displaced axially, and then the nuts retightened to adjust the gap between the lower leg of the forming member and the lower wall of the forming duct.

Preferably, the lower leg 372 of the forming member 351 extends to a point approximately co-terminal with the outlet end of the forming conduit 350. The posterior portion of the forming member 25 preferably projects backward.

-8787 an i..

from the inlet end of the forming conduit for approximately half its total length. Also, the radius of the rounded base or cove portion of the forming member is preferably approximately one-fifth the height of the forming conduit orifice. This provides a smooth transition from the separating members of the separating device to the forming member and then into the forming conduit.

The forming member 351 is of relatively uniform width. The forming member can be formed, for example, by flexing an elongated elastic strip into the shape illustrated in Figure 33. In the illustrated embodiment, the width of the strip is approximately one-quarter the width of the forming duct outlet opening, which in turn is approximately two-thirds the width of the forming duct inlet opening. The training limb may be configured in any other way. For example, the rear end portion may be wider than the front end portion. Furthermore, the transition from the narrow front portion to the wide rear end portion may be gradual, such that the lower leg of the training limb has a triangular shape. Similarly, the upper leg may have

-8888 a triangular shape, while the rounded cove portion of the formation member may be relatively uniform in width or in the shape of an inverted hourglass.

As will be appreciated by those skilled in the art, the forming duct and assembly 302 of the forming member shown in Figures 32 to 34 may have general application in cushioning converting machines such as the 10 cushioning converting machines shown in United States Patents Nos. 4,968,291 and 5,123,889.

Now with reference to Figures 35-38, an interlocking mechanism is generally indicated in 385. This interlocking mechanism is particularly useful in the converting machine 20 as protection against the feeding of the supply material, if the cover 37 of the rear unit 31 has been removed or is not properly secured in place. For this purpose, an interlock switch 387 and a 2-axis piston 388 are secured respectively to the housing 43 of the front unit 30 and the cover 37 of the rear unit 31. The interlock switch can be mounted, for example, by a bracket 389 to one of the side frame members 92 of the housing with its piston 25 receiving the rear opening end

-8989 generally level with the rear wall 390 of the front unit box 44. The drive piston 388 is mounted to the projection 74 on the front end of the rear unit cover in a location that corresponds to the drive switch, such that when the cover is secured to the rear unit base, the drive piston actuates the interlock switch to close a circuit, which enables the operation of the feed/sewing mechanism. More specifically, the interlock switch can be connected in series with the motor or, alternatively, the interlock switch can control a relay connected in series with the motor, such that the relay must be closed to allow the motor to operate. Of course, other electrical schemes or devices may be employed to effect the interlocking in response to the coupling of the interlocking switch and the actuating piston, when the cover is properly secured in place, or other key and lock coupling devices.

Now, with reference to Figures 39 and 40, yet another feature of the invention is illustrated in connection with the conversion machine 20. As shown, a spring-loaded retaining mechanism 393 is mounted to the carriage.

-90.111 1.,.

133 of the moving blade, preferably in the middle along its length. The retaining mechanism is oriented such that its piston 3 94 will be engaged and pressed by the transverse frame member 5 when the moving blade carriage moves to its highest position, which corresponds to when the slotted crank is turned sufficiently to operate switch 150 to energize the feed motor. The piston 394 has a sufficient stroke to push the blade carriage 10 away from the cross-frame member a sufficient distance to cause the slotted crank 144 to move away from the switch 150, so that the switch is no longer actuated as best shown in Figure 40. This is advantageous because it prevents inadvertent feeding of the product, as it prevents the switch from being activated when the machine is idle and no one is operating the handle. In this way, if handle 141 is swinging into its feed position and released, as should happen after a strip of product has been produced, additional product will not continue to be fed from the machine while the handle remains unattended. Conversely, the retaining mechanism will cause the handle to move out of its feeding position, so

-91.111 1 prevents the possibility of any inadvertent or unattended feeding of the product.

As will be seen, the retaining mechanism 393 could be positioned in any other way on machine 5 to achieve the same result, such as by positioning the retaining mechanism so that it acts directly on the slotted crank. Another possibility is to select a switch that has a return spring element capable of moving the slotted crank 10 far enough away to deactivate the switch. Still other arrangements, too numerous to mention, can be employed to achieve in a variety of ways the desired function of preventing the switch from being activated when the handle or machine is unattended.

Now with reference to Figures 43-45, the cushioning conversion machine 300 and the support platform 306 are shown as modified according to the present invention, to provide for the quick and easy assembly of the front and rear units 304 and 305 and their attachment to the platform without the need for tools. As shown, the front unit 304 of the machine has a cavity structure 400 in its rear wall 390, which forms a groove 401 to slide into the projection 402 at the front end 25 of the rear unit 305. The projection 402 is

-92Jll 1.

sliding in and out of the groove in a direction perpendicular to the longitudinal axis of the machine. The cavity structure 400 and the projection 402 cooperate to retain the front and rear units together against separation in a direction parallel to the longitudinal axis of the machine.

As best shown in Figures 46 and 47, the cavity structure 400 forms a U-shaped cavity with the rear wall 390 of the front unit 304, the cove of the U generally being coextensive with the inlet opening 404 of the front unit. The cavity structure 400 generally comprises a pair of laterally separated side members 406 and an end member 407 extending between the side members 406. The side and end members 406 and 407, which may be made of metal, plastic or other suitable material, are generally L-shaped in cross section, with one leg of the L being secured to the back wall 390 by suitable fasteners (or other suitable means) and the other flange forming a rail or flange 408, 409 separated from the back wall 390 to form respective sides of the groove 401. Slot 401 preferably opens in one direction by separating from the side of the front unit that is attached to platform 306 in the manner described below.

-9393

As preferred, a backing plate made of metal or other rigid material may be used to stiffen the back wall 390 and further provide an anchorage for fasteners such as bolts or screws used 5 to secure the side and end members to the back wall, with the bottom wall sandwiched between the end and side members and the backing plate as shown.

As shown in Figures 46 and 47, the end member 407 is provided with a threaded hole 415 in its flange to receive a hand-tightening screw (not shown in Figures 46 and 47). The projection 402 of the rear unit 305 has a hole 416 in it, which aligns with hole 415 when the projection is fully inserted into the groove 401 against the

The back wall 417 of slot 401, so the hand-tightening screw can be threaded into aligned holes to clamp the projection against removal from the slot. As preferred, a hand-tightening screw 20 is used to avoid the need for tools, although it will be appreciated that other types of screws or fasteners may be used, including those that may require a tool to be used, although it is less advantageous. By way of another specific example, one or more manually operated pins 25 can be used to retain the

-9494

-111 ί protrusion from the rear unit to the front unit. As another alternative, the hand-tightening screw that is threaded into the aligned openings in the projection and end member 407, can be replaced by a spring-deflected piston, which can be retracted against the spring deflection to allow the projection to slide in or out of the groove and extended to pass through the openings, when aligned, thereby holding the projection in the groove.

Therefore, the front unit 304 can be assembled with respect to the rear unit 305 in an easy and simple manner without the need for tools.

Furthermore, the front and rear units of machine 300 can be easily and quickly attached to the vertical or frame portion 307 of the platform 306, again without the need for tools. As shown in Figures 43, 44, and 47-49, the front unit 304 is provided on its underside or base wall 420 with hooks 422 that engage with the keyway holes 424 in the frame portion 307 of the platform 306. As illustrated in Figures 48 and 49, each fastener 422 can be in the form of a key having a shank 423 and an enlarged head 425. The shank portion has a threaded hole at its end opposite the head portion to receive a fastener

-9595

426, so the key can be secured to the lower wall 420 of the front unit housing 320 as illustrated in Figures 48 and 49. The stem separates the head away from the lower wall to form an annular hook recess 428 for engagement in the keyway groove 424.

As best shown in Figure 50, each keyway 424 is formed in the wall of the tube bent to form the frame 307. Each keyway has an enlarged circular upper portion 430, sized to receive the respective key head, and a relatively narrow lower groove portion 431. The lower portion 431 of the groove is wide enough to receive the shank of the respective key, but too narrow to allow the key head to pass through it. As shown in Figure 45, the platform is provided with two such keyholes positioned symmetrically with respect to the longitudinal axis of the platform to receive correspondingly aligned keys 422 on the front unit.

Provision is also made for hanging the rear unit 305 on the frame portion 307 of the platform 306. As shown in Figures 43, 44 and 51,

-96JIE 1 The rear unit is provided with a transversely extending hook member 436 secured to the lower wall 337 of the rear unit housing 321. The transversely extending member is in the form of an L-shaped cross-section bar having an upper fork 437 attached by a plurality of fasteners 438 (or other suitable means) to the lower wall 337. As shown in Figure 51, the fasteners 438 extend through the bottom wall 337 and also through the stiffening member 338, noting that the box may be made of plastic of a thickness that may not have sufficient strength to prevent bending of the box when the rear unit is supported on the platform. The cross-hook member also has a lower leg or flange 430 separated from the lower wall 337 of the rear unit housing to form a hook recess 441 into which the platform cross-frame member 312 can be engaged. In this manner, the rear unit can be suspended from the platform cross-frame member 312, which cross-frame member functions as an attachment point for the hook member.

Returning now to Figures 52 through 60, the method of assembling the 300 machine on the 306 platform is illustrated. As shown in Figure 52, the front unit

-9797

LUCI.

304 It is initially attached to platform 306. This is done by placing the front unit 304 adjacent to platform 306 with the enlarged heads of the 422 keys aligned and then inserted into the 5 upper portions of the keyway holes.

Then, in the front unit it is lowered as shown in Figure 53, so it will be supported by the platform.

Next, the protrusion 402 of the rear unit 10 305 is aligned horizontally with the slot 401 on the front unit 304 and then moved to the platform 306 with the protrusion sliding into the slot as depicted in Figure 54. When the projection has almost been fully inserted into the groove in the rear wall of the front unit, the hook member 436 in the rear unit will be making butt contact against the transverse frame member 312 of the support platform frame 307 as shown in Figures 55 and 56. At that point, the front and rear units are displaced vertically upwards 20, enough to raise the hook member above the transverse frame member as shown in Figures 57 and 58, so that the rear unit can then be displaced towards the frame portion of the platform and then lowered 25 to engage the hook over the member.

-9898 cross frame as shown in Figures 59 and 60. Then, as shown in Figure 59A, a hand-tightening screw 450 is screwed into the aligned hole 415 in the projection 402 and the hole 416 in the front unit cavity structure 400, to prevent the projection from being pulled out of the slot during use. Also, to prevent the machine from being accidentally lowered from the frame portion 307 of the support platform 306, the front unit is provided with threaded holes 452 (Figure 48) that are aligned with the holes 453 (Figure 45) in the joining lugs 455 provided on the support platform as shown in Figure 445. The hand-tightening screws 4 57 can be passed through the joining lugs and secured in the threaded holes 452 in the front unit to hold the front unit against longitudinal movement relative to the frame portion of the support platform.

Now, with reference to Figure 61, it will be observed that the machine 300, assembled to frame portion 307 of platform 306 as described above, can be used in a different orientation than vertical. As shown in Figure 61, the machine 300 and frame portion 307 can be supported on the upper surface 460 of table 461, preferably by cups of

-9999 suction or similar clamping devices, which prevent the machine from moving across the top of the table. In this arrangement, the legs 308 (Figure 43), normally used to hold the vertical frame portion 307, are replaced by the supply roll clamping members 465. As shown, the supply roll clamping members are generally L-shaped, with each clamping member attached to a respective leg of the platform frame portion instead of leg 308. As shown, a leg 468 of the L-shaped clamping member is formed by a tubular piece, which may be telescoping over the respective leg of the frame member. The other leg 469 is provided with a support forming the groove 470 to receive the end of a roll holder, such as a shaft extending through the core of the supply roll 472 supported thereon. As will be seen, the supply roll is supported in a cantilevered manner on the side of the table, its weight counterbalanced by the weight of the front unit supported on the table.

Now, with reference to Figures 62-66, another type of cushioning conversion machine is generally indicated by the reference number 500. Machine 500 is largely the same as machine 300 described above, except for the differences.

-100100 <ιικι which are described below. In any other way, reference may be made to machine 300 (and consequently to the above description of machine 20) for details of machine 500 that are not described or mentioned below.

Therefore, the machine 500 comprises a rear or forming unit 504 and a front or front unit 505. The forming and front units are coupled together by the quick-connect/disconnect structure 507, which provides a strong connection between the forming and front units. As desired, the machine coupled in this way may be supported on top of a table or other horizontal (or even inclined) surface without the frame described above in relation to Figure 61. As shown, the lower wall 508 of the outer case 509 of the front unit 505 is then fitted with rubber or plastic feet 510, or other anti-slip devices to prevent the machine from moving across the top of a table. The lower portion or base of the forming unit 504 box, which is shown more fully in Figure 64, can be similarly equipped with anti-slip devices such as rubber or plastic feet 511; these feet are provided on the lower wall 512 of the base of the

-101101 former box, which is coplanar with the lower wall of the front box base, when the former and the head or front part are assembled together.

The quick-connect/disconnect structure 507 includes a projection 514 at the front end of the base portion 515 of the outer case 516 of the forming unit 504. The projection 514 is transversely slidable in and out of a vertical opening, the slot/cavity 518 that extends laterally in the front unit 505. The cavity 518 is formed between an outwardly offset flange portion 512 of the rear wall 520 of the front unit housing 509 and a laterally extending back plate 522. The back plate 522 extends between and is secured at its ends to the side plates 523 and 524 of the front unit frame 525. The width and thickness of the cavity closely match the width and thickness of the projection 514 to provide a slip-fit ​​with minimal clearance for precise positioning and axial alignment of the forming unit with respect to the front or head unit. Although not shown, one or more fasteners or other means may be used to secure the back wall 520 to the back plate 522.

A 527 bra with a button is also provided.

-1020. lilili.

102 to secure the projection in the cavity in essentially the same manner as described above, in relation to the fastener 450, the threaded body of the fastener being screwed into a threaded hole in the backplate, i.e., aligned with holes in the projection 514 and the flange portion 519.

Various other modifications are illustrated in Figures 62 and 63. As shown, the guide conduit 530, also referred to as a joining conduit, can be attached to the cross-frame member 531 by a bracket or brackets 533 and fasteners 534, or conversely, by being included in a separately removable blade assembly 535, as was the case in the embodiments described above.

With regard to the blade assembly 535 and as further shown in Figures 6, 7 and 68, the mounting screws 538 for the blade clamp block 538 can be inserted from the top (as oriented in Figure 62) through the holes 540 at the ends of the stationary blade clamp block to secure the blade clamp block to the lower frame member 541 of the guide frame 542 (Figure 62). This allows the mounting screws to be conveniently tightened or loosened from the top of the main unit or from the top.

-103103

The upper cover of the main housing (upper case portion) 544 (Figure 62) has been removed from the case base 545. When the mounting screws 538 are loosened, the adjusting screws 547 can be moved in or out to adjust the position and alignment of the stationary lower blade 548. For this purpose, the holes 540 are enlarged to allow forward or backward adjustment of each end of the blade clamp block. Once adjusted, the mounting screws 538 can be tightened to secure the stationary blade in place. As you will notice, the adjustment screws 547 may be accessible from the front of the main unit. The adjustment and mounting screws may also be fitted with Nylok nylon patches or another suitable means to prevent loosening due to vibration.

Another modification illustrated in Figure 62 is the provision of shock-absorbing stops 553 and 554 at the respective ends of the stroke of the moving blade carriage 555. The stops may be O-rings made of a suitable elastomeric or other elastic or cushioning material. As shown, the O-rings are fitted to the ends of the guide posts 556. In Figure 63, it can be observed that the blade carriage 555 may include sleeve bearings 558

-104104 that slide on the guide posts. Returning to Figure 62, it can be seen that the flap door 560 is also referred to as a duct cover; it can be a single piece with and thus a leaf of a joint 561. The other leaf 562 of the joint is attached to the upper cover of the main housing 544 by suitable means and is connected to the duct/flange cover 560 by a joint bolt 563 or a plurality of axially aligned joint bolts. As shown, the duct cover may be stepped at 565 to accommodate the outwardly offset peripheral flange 566 of the upper cover of the main housing. The hinged connection is configured so that the duct cover cannot open beyond 90° from its closed position. This prevents the duct cover from swinging about its center when the machine is supported in a vertical orientation with the head or main section at the top, ensuring that gravity always acts to return the duct cover to its closed position. Alternatively, the duct cover can be diverted in any other way to its closed position, such as by a spring or similar.

As shown in Figure 62, the retainer 570 (also referred to as a tension block) on each floating shaft adjusting screw 572 (referred to in the

-105105 ii.ΞΙΐυ .

(previously used as a tie-down member), may be provided with a nylon-tipped adjusting screw 573, which intersects the threaded hole in the tension block 570 for the tension adjusting screw. The nylon portion of the adjusting screw 573 can be tightened onto the threads of the tension adjusting screw to provide anti-vibration mounting. Also, the end of the groove 575 on each side of the frame member for the floating shaft 576 can be positioned in such a way that it stops the movement of the floating shaft toward the other shaft before the gear-like member of the floating shaft fully interlocks with the other gear-like member. This prevents or minimizes wear on gear-like members when the gear-like members are rotated without sheet-like production material between them, such as during machine loading or when a supply of provision material is being pulled out.

Figures 62 and 63 also show a different mounting arrangement for the interlock switch 580, which is adapted to accommodate the downward placement of the forming housing cover 581 onto the forming housing base 515. In this arrangement, the switch is oriented to receive and is operated by a key 583 oriented

-106106 vertically, which is mounted to the form housing cover as illustrated.

The forming housing cover 581 is shown more fully in Figures 69-71. As illustrated, the forming housing cover may be provided with a handle 585, usually centrally located, to facilitate lifting the cover. The cover also has a bell-shaped front rim portion 586, which aligns with a continuation of the same at the rear of the main housing base 545 (Figure 63).

With reference to Figures 64-65, a modified supply roll holder arrangement in 589 is illustrated. The supply roll holder arrangement includes a pair of laterally separated bracket-like protrusions 59 0 to support the supply roll. Each bracket has a lower J-shaped portion 591 forming a vertically upward, preferably inclined, opening 20, the slot 592 to receive, including the ends of the supply roll holder (such as a bar or a holder as described in the related application No. 08/267,960 filed on June 29, 1994) on which a supply roll can be centrally supported 25 for rotation, such that

-107107 The supply material can be unwound from the supply roll for passage through the machine. The body 594 of the J-shaped lower end portion of each bracket can be provided with a flange or projection 595 for added rigidity against lateral bending.

The upper portion 597 of each roll-provision bracket 590 is generally L-shaped and configured for attachment to the base 515 of the forming box 10 at a respective corner thereof, preferably in a wrap-around fashion. The legs 598 and 599 of the L are secured by suitable means, such as fasteners 600, respectively to the back wall 601 and the respective side wall 602 of the base of the forming box. As will be seen, the upper L-shaped portions of the brackets provide rigidity and strength or reinforce the corners of the forming box base to support the weight of a roll of supply supported there, as well as any shock or other forces that may occur during the loading of the roll of supply onto the brackets. As stated above, the forming box can be made of plastic and the brackets allow the plastic box to carry larger loads than it could carry in any other form.

-108108

Calle

Figures 64 and 65 illustrate another modification.

As preferred, the inlet end of the forming or shaping conduit 604 is flared outward in a trumpet-like shape in 605. This facilitates the passage 5 of the sheet-like provisioning material into the forming conduit. It also prevents any tearing along the edge of the provision material similar to a blade of the hook against the leading edge of the forming channel, as would result in any other 10-way tearing of the provision material. As can also be seen in Figures 65 and 66, the outlet end 610 of the shaping duct may have its side walls 611 rounded inwards at their junction with the lower wall 612 of the shaping duct.

With reference now to Figures 72-75, it will be noted that a blade retainer assembly 620 can be provided to hold the moving blade carriage 555 in its raised or open position, as may be desired during transport or in any other way.

The blade retainer assembly includes a retaining member 622, here in the form of a retaining bolt that is movable between (i) an enabling position which permits movement of the moving blade from its

-109109 feed position to its cutting position and (ii) a disable position, which prevents such movement.

In the illustrated embodiment, the retaining pin 622 is guided for longitudinal movement by a bolt housing 624 secured to the side frame plate 523 in an opening therein adjacent to and outside the path of movement of the relatively adjacent crank 625, also referred to as the lifting lever. At its inner end, the retaining pin is provided with a transversely extending latch pin 627. The locking bolt is selectively engaged in either of the two grooves 62 8 and 62 9 provided at the lower end of the housing. The grooves, which intersect at right angles, have different axial depths to define two axially offset positions of the locking bolt respectively, corresponding to the locking and disabling positions of the locking bolt.

At its outer end, the retaining bolt 622 20 has a button 622 or other suitable device to facilitate manipulation of the retaining bolt between its enabled and disabled positions. Interposed between the button and the housing is a spring 33 or other deflecting element to deflect the retaining bolt 25 axially outward. The axially most

-110110 exterior and thus the enabling position of the retaining bolt is determined by the engagement of the bolt bolt 627 in the deeper groove 628 at the end of the housing 624, while the axially 5 more interior position and thus the disabling position of the retaining bolt is determined by the engagement of the bolt bolt in the shallower groove 62 9 at the end of the housing. The retaining bolt can be moved from one position to the other by pushing button 632 inwards against the spring's deflection force sufficiently to move the bolt bolt axially out of the slot in which it was previously engaged, after which the button can be rotated 90° to align the bolt bolt with the other slot. Then the button can be released to allow the deflection force of spring 633 to move the retaining pin outward until the bolt engages the bottom of the other slot.

When the retaining pin 622 is in its enabled (or released) position 20 as shown, the inner end of the retaining pin will be on one side of the path of movement of the relatively adjacent lifting lever 625 as shown in Figures 72 and 73. Consequently, the lifting lever is free to move between its positions

-111111 feed and cut for normal machine operation. However, when the retaining pin is in its disabled (or locked) position, the inner end of the retaining pin will be located in the path of movement of the lifting lever and will thus block the movement of the lifting lever to its cutting position. Preferably, the retaining pin is positioned so that the lifting lever will be held in the intermediate position 10 to which it is pushed by the retaining mechanism.

93 spring-loaded as described above (Figure 39) so that the operating switch will not be held in an energized position. In the illustrated embodiment, the retaining pin is positioned so that it can also be used alternatively to retain the blade assembly in its closed or cutting position. That is, the handle can be moved to close the blade assembly and then the retaining bolt attached behind (instead of in front of) the lifting lever 2 0 to prevent its movement back to its open position.

As will be seen, the 620 blade retainer assembly can be placed in any other way on the machine to achieve the same result, such as by the 25 placement of the retainer assembly, in such a way that it acts

-112112

.....lili.

on the moving blade carriage 555, the handle 638 or other moving member of the cutting assembly or an operating assembly. Also, other arrangements may be used, for example to provide a plurality of 5 separate retaining surfaces along the axis of the retaining bolt or other member and to provide the bolt with a transaxially extending butt contact surface selectively engageable with the retaining surfaces to define the plurality of 10 axially offset positions of the bolt, with at least one of the positions corresponding to the enabling position of the retaining bolt (or other member) and another of the positions corresponding to the disabling position of the retaining bolt.

Figures 72 and 73 illustrate another modification. As shown, the cross-frame member 531 can be configured and positioned to allow the lifting levers 625 and the pivot or crankshafts 644 to which they are attached to be pulled axially inward, clearing the shaft or bearing bushings 645 for them in the side-frame members 523 and 524. This is advantageous for facilitating the repair or replacement of the lifting levers. Also, frame components no. 25 must be disassembled to remove the levers.

-113113 lifting, in such a way that the parallelism of the side plates will not be destroyed by field repairs. When assembled to the side frame members, the lifting levers and attached crankshafts 5 are held axially in place by press-fit rings 646. The ends of the crankshafts extend outward and through an opening in the side wall of the outer case of the main unit for attachment to it of the handle 638.

For mounting the ends of handle 63 to the crankshafts 644, the mounting blocks 650 are keyed and/or hinged to the outer ends of the crankshafts. Each mounting block has a symmetrical arrangement of threaded holes to receive two respective screw fasteners 651 used to secure a respective handle mounting 653 to one end of the handle and attach it to the mounting block. In the illustrated embodiment, the handle includes a U-shaped tubular member 654, the base or recess of which is surrounded by a tubular handle holder 656 made of foam rubber or similar material. Telescopically connected at the ends of the tubular member are the cylindrical ends of the handle supports 653. The other ends of the handle supports form the flat mounting lugs or feet 657, provided with openings 659.

-114114

... JIE (Figure 75) which corresponds to the holes in the mounting blocks. Preferably, provision is made for rotational adjustment of the handle ends in relation to the respective lifting levers to adjust the manufacturing tolerances, so that the lifting levers can be brought into precise parallel alignment. For this purpose, the openings 659 are circumferentially elongated as shown in Figure 75 to provide such rotational adjustment.

During assembly, the handle 638 can be attached to the mounting blocks 650 by the fasteners 651. The lifting levers 625 can then be precisely positioned in parallel relation to the circumferentially elongated openings 659 to allow rotational adjustment of the lifting levers relative to the ends of the handle. Once adjusted, the 651 fasteners can be tightened to ensure the adjusted relationship between the lifting levers and the handle.

Now, with reference to Figures 76 and 77, the additions to platform 306 for the cushioning conversion machine 300 are illustrated. As shown, platform 306 can be provided at its upper end with a handle 662 and at its lower end with one or more rollers or wheels 664 to facilitate movement of

-115115 the machine from one place to another. As will be seen, the handle, which is attached to the upper end of the vertical frame 307 of the platform, can be grasped and pulled to the right in Figure 76 to swing the machine and the platform clockwise with the rounded end of the platform's legs 308 functioning as a fulcrum with the floor or other horizontal surface on which the platform is supported. As preferred, the rollers 664 are offset 10 vertically upwards and horizontally from the lower surface of the platform, so that they will engage the floor when the machine has been rotated preferably through approximately 30° to approximately 35° from the vertical. Furthermore, it is advantageous that such a coupling point of the center of gravity of the machine and the platform will not have rotated more than approximately 20° beyond a vertical plane that intersects the support point and preferably no more than 10°, so that the coupling of the roller with the horizontal surface, the machine and the platform can be easily rolled along the horizontal surface. This arrangement minimizes the amount of weight that must be supported on the handle during movement as the machine is rolled from place to place.

-116116

A retaining stop 668 is also provided to limit machine oscillation to a prescribed amount. For example, the retaining stop may be positioned to prevent the center of gravity of the machine and platform from moving about center with respect to the rollers 664, or to limit oscillation about center with respect to the roller axis to within 20°, more preferably within 10°, and even more preferably within 5°.^eitherFurthermore, the retaining stop must be positioned so that it engages with the floor and thus further stops the rotation before the center of gravity of the machine and platform has moved through a vertical plane intersecting the engagement point of the retaining stop with the floor, thus preventing the machine and platform from falling once the stop has engaged with the floor even if the platform handle 662 is released by the assistant. The platform legs may also have anti-slip devices, such as rubber strips 670, 20 provided on their lower sides.

Now, with reference to Figures 78-80, further modifications of a cushioning conversion machine according to the invention are illustrated. For use of the machine 500 where it cannot be easily connected to an external source of electrical power, the

The AC motor normally used -117 may be replaced by a DC motor, which may be powered by a battery 680 housed in or carried by the machine, or provided as a separate battery pack that may be placed adjacent to the machine. In the particular embodiment shown in Figures 78-80, the battery 680 (which, for example, may be a bank of one or more rechargeable lead-acid batteries) is supported on a battery holder 681. The illustrated battery holder is an extending tray that has its ends supported on the leg portions 3 08 of the platform 3 06, which projects beyond the machine opposite the leg end supporting the supply roll 683. The battery can be connected by suitable wiring (not shown) to the motor in the front 505 unit, such as by a wiring harness that runs along the outside or through the tubular components from which the platform is formed. A harness connector may be provided at the point of separation between the vertical portion of the platform and either or both of the legs that hang over the wiring path to facilitate assembly and disassembly of the platform as described above. The ends of the wiring harness may also terminate in electrical connectors for quick connection to a connector to which the wires

The motor's terminals -118118 are already connected to a connector to which the battery cables are connected. The machine assembly can also be provided with a battery charger, which can be conveniently supported on the battery tray along with the battery or batteries. It should also be noted that other types of motors can be used to drive gear-like members, such as, for example, a fluid motor. For a fluid-powered motor, a power storage device 10 can include a compressed air tank instead of a battery. The compressed air tank can be easily mounted on the platform legs at the location of the illustrated battery holder. Other portable power sources for the motor 7 can also be used. For example, the machine can be powered by a vehicle battery and/or an electrical system. The battery may also have an associated solar panel or panels to recharge the battery.

As shown in Figures 78-80, the 20 platform 306 can be supported for rolling on a floor surface by small casters 686 or similar, and preferably by small support casters. As illustrated, each leg has a small caster 686 attached at its toe and heel for four-point rolling support of the 25 platform and the machine supported on

-119119 her. As another modification, the keys 422 and the keyway holes 424 described above may be replaced by hand-tightening screws 688 that pass through the holes in the frame portion of the support platform for securing in the threaded holes in the front unit, in a manner similar to the hand-tightening screws 457, which extend through the joining lugs on the support platform. 3

Now, with reference to Figure 81, another form of the platform leg is illustrated. The platform leg 690 includes a vertical tube 691 in or on which a leg of the upper frame can be telescopingly connected. The vertical tube is secured at its lower end by welding to the ends of the longer legs of the oppositely extending L-shaped members 993 and 994. The other legs, or shorter legs, of members 693 and 694 pivot downward from the longer legs to rest on top of the floor, providing a wide base for the platform. Members 693 and 694 may be tubular, and small wheels may be attached to their ends to roll the platform from one location to another. For a stationary installation, the ends of members 693 and 694 may have rubber feet or

-120120 rubber or other anti-slip means secured to them, to prevent the platform from sliding across the floor. The leg also includes a bracket 696 to receive one end of a supply roll fastener. As will be appreciated, the leg can be used with another leg in place of the legs described above on the machine platform.

Cushioning converting machines according to the present invention provide the production of a low-density cushioning product. A cushion produced on a cushioning converting machine according to the present invention, using a 68.58 cm (27 in) wide supply material composed of 3 plies of 13.62 kg (30 lb) recycled APC Kraft paper, has been found to have the following properties:

Height 5.58cm

Width 19.35cm

Yield 0.92 m³/136.8 meters of the roll

Density 10.73g/1

Loss of skin fold 8.33%

Therefore, a packing strip is provided that has a height of approximately 5.08 cm to 5.71 cm (2 to 2.25 inches), a width of 19.05 cm to 20.32 cm (7.5 to 8 inches), and a density of

-121121 approximately 10.25 g/1 to 11.3 g/1 (0.64 to 0.7 lbs/ft³) using three 68.58 cm wide (27 inch) folds of 13.62 kg (30 lb) Kraft paper.

Although a particular feature of the invention may have been described above with respect only to one of the illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.

Although the invention has been shown and described with respect to various preferred embodiments, it will be apparent that equivalent alterations and modifications will occur to others skilled in the art, from reading and understanding this specification. Therefore, the present invention includes all such equivalent modifications and alterations.