Cushioning conversion system with universal output chute

Abstract

 A cushioning conversion machine system includes a stock supply assembly, a conversion assembly for converting the stock material into a cushioning product and providing it through a machine outlet, and a cushioning product transferring system including first and second series of drive elements spaced to form therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, each of the first and second series of drive elements being adjustably interconnected for varying the path of the passageway.

Description

Technical Field

[0001] The invention herein described relates generally to a cushioning conversion system and, more particularly, to such a system that affords flexibility in the directing of product exiting from a conversion machine.

Background Of The Invention

[0002] In the process of shipping an item from one location to another, a protective packaging material is typically placed in the shipping case, or box, to fill any voids andlor to cushion the item during the shipping process. Some conventional protective packaging materials are plastic foam peanuts and plastic bubble pack. While these conventional plastic materials seem to perform adequately as cushioning products, they are not without disadvantages. Perhaps the most serious drawback of plastic bubble wrap andlor plastic foam peanuts is their effect on our environment. Quite simply, these plastic packaging materials are not biodegradable and thus they cannot avoid further multiplying our planet's already critical waste disposal problems. The non-biodegradability of these packaging materials has become increasingly important in light of many industries adopting more progressive policies in terms of environmental responsibility.

[0003] The foregoing and other disadvantages of conventional plastic packaging materials have made paper protective packaging material a very popular alternative. Paper is biodegradable, recyclable and renewable, making it an environmentally responsible choice for conscientious industries. Furthermore, paper protective dunnage material is particularly advantageous for use with particle-sensitive merchandise, as its clean, dust-free surface is resistant to electrostatic buildup.

[0004] While paper in sheet form could possibly be used as a protective packaging material, it is usually preferable to convert the sheets of paper into a pad-like or other relatively low density dunnage product. This conversion may be accomplished by a cushioning conversion machine, such as the machine disclosed in commonly assigned U.S. Patent No. 5,123,889. The therein disclosed cushioning conversion machine converts sheet-like stock material, such as paper in multi-ply form, into a pad-like dunnage. The stock material usually consists of two or three superimposed webs or layers of biodegradable, recyclable and reusable 30 pound Kraft paper rolled onto a hollow cylindrical tube. A thirty-inch wide roll of this paper, which is approximately 450 feet long, will weigh about 35 pounds and will provide cushioning equal to approximately four fifteen cubic foot bags of plastic foam peanuts while at the same time requiring less than one-thirtieth the storage space.

[0005] Specifically, the aforesaid conversion machine converts the stock material into a continuous strip having longitudinally extending pillow portions that are joined together along a connected central portion. This strip is severed as by cutting into sections of a desired length. The cut sections usually are guided away from an outlet opening of the machine by an output chute, as in the manner shown in the aforesaid patent. Also known are curved chutes such as shown in commonly assigned U.S. Patent No. 5,487,717. The output chutes shown in the aforesaid patent and patent application are static devices, in that they do not operate to advance the cut sections along the length thereof.

[0006] Conversion machines also have had associated therewith output chutes which are active devices that propel the cut sections along the length thereof. These active chute devices included devices which convey the cut sections along a straight path and other devices that convey the cut sections along a curved path. In commonly assigned U.S. Patent Application No. 081672,856, a cushioning conversion machine is equipped with an output chute composed of a pair of parallel arcuate arrays of rollers which are rotatably driven to advance a cut section from the outlet of the machine to a remote location. The path of the output chute, however, has a fixed curved shape. For any given application, a new chute assembly heretofore was designed, stocked and built to provide the desired path for the cut sections exiting from the machine.

Summary Of The Invention

[0007] The present invention provides a cushioning conversion system including a cushioning conversion machine and a universal output guide chute that affords flexibility in the path along which the cut sections are guided from the outlet of the machine to a remote location, without undue cost and with ease of assembly. More particularly, the invention provides a single output chute configuration that can be easily configured during assembly to provide any one of a variety of guide paths for the cut sections. In a preferred embodiment, the output chute includes drive elements for advancing the cut sections along the guide path.

[0008] In accordance with one aspect of the invention, a cushioning conversion system includes a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and an output chute including first and second series of drive elements spaced to form therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, each of the first and second series of drive elements being adjustably interconnected for varying the direction and shape of the passageway.

[0009] In accordance with another aspect of the invention, a cushioning conversion system includes a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and an output chute including first and second guide assemblies spaced apart to define therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, the first and second driving assemblies having first and second driving surfaces, respectively, the driving surfaces being adjustable to vary the direction and shape of the passageway. In one embodiment of the invention, the driving surfaces are each composed of plural segments that are parallel with respective segments of the other driving surface.

[0010] In accordance with yet another aspect of the invention, a cushioning conversion system includes a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and an output chute including first and second series of articulated guide segments forming therebetween a passageway for the cushioning product, each of the first and second series of guide segments being adjustably interconnected for varying the direction and shape of the passageway.

[0011] In accordance with a further aspect of the invention, a cushioning conversion system includes a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; means for transporting the cushioning product along a passageway; and means for adjusting the shape of the passageway.

[0012] In accordance with a further aspect of the invention, a cushioning conversion system includes a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and an output chute including first and second drive elements spaced to form therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, each of the first and second drive elements being adjustably interconnected for varying the path of the passageway.

[0013] The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.

Brief Description of the Drawings

[0014] In the annexed drawings:

Fig. 1 is a side elevational view of a cushioning conversion system comprising a conversion machine and the universal output chute of this invention;

Fig. 2 is an enlarged perspective view of the universal output chute which includes spaced apart series of drive elements defining a pathway therebetween for cut sections of cushioning;

Fig. 3 is a partial plan view of one of the series of drive elements, partly broken away in section;

Fig. 4 is a perspective view of a link of the output chute;

Fig. 5 is an exploded perspective view of an alternate embodiment output chute in accordance with the present invention;

Fig. 6 is a perspective view of a guide assembly used in another embodiment of output chute in accordance with the present invention;

Fig. 7 is a fragmentary plan view of a portion of the guide assembly of Fig. 6; and

Fig. 8 is a fragmentary side view of an additional alternate embodiment guide assembly in accordance with the present invention.

Detailed Description Of The Invention

[0015] Referring now to the drawings in detail and initially to Fig. 1, a cushioning conversion system according to a preferred embodiment of the invention is designated generally by reference numeral 8. The system 8 comprises a cushioning conversion machine 10 and an output chute 12. The machine 10 converts sheet stock material into relatively low density cushioning products, herein also referred to as pads, whereas the output chute 12 transfers the pads from an output or exit opening 14 of the machine to a remote location where it is desirable to present the pad.

[0016] The machine 10 includes a housing 20 having at its upstream end a supply assembly 22 for supplying stock material to be converted into a cushioning product. The housing has mounted therein a conversion assembly 26 for converting the stock material into a continuous strip of cushioning product and a severing assembly 28 located between the conversion assembly and the output chute 12, the latter being located at the downstream end of the machine housing 20. The severing assembly severs the strip into discrete sections or cushioning pads of a desired length. (The terms "upstream" and "downstream" are used herein in relation to the direction of flow of the stock material through the machine 10.)

[0017] In the illustrated embodiment, the stock supply assembly 22 includes, as is preferred, a shaft 32 for supporting a roll of sheet stock material (not shown) and a constant entry roller 34 for guiding the stock material to the conversion assembly 26. The stock material may consist of one or more plies of sheet material, for example three superimposed webs of biodegradable, recyclable and reusable thirty-pound Kraft paper. The conversion assembly 26 includes a forming assembly 36, such as a cooperating three dimensional wire former 38 and converging chute 40 as is shown in Fig. 1, and a feed/connecting assembly 42 including a pair of rotating members such as gears 44 for pulling the stock material through the forming assembly and feeding it out through an outlet to the cutting assembly 28 and then to the output chute 12. The severing assembly 28 may include one or more blades or other means acting to sever the continuous strip of padding at the appropriate times. If desired, the machine may be supported on a stand or cart 46.

[0018] For purposes of the present invention, the illustrated conversion machine 10 is an example of one of many different types of conversion machines that may be used in practicing the present invention. For further details of the illustrated conversion machine and other conversion machines that may be used, reference may be had to U.S. Patent Nos. 4,937,131, 4,968,291 and 5,123,889, and U.S. Patent Application Nos. 08/607,607 and 081482,015, as well as other patents assigned to Ranpak Corp. Also, it should be understood that still other conversion machines may be used in practicing the present invention.

[0019] As best shown in Figs. 1-3, the output chute 12 includes upper and lower guide assemblies 66 and 68, respectively. In the illustrated embodiment, the guide assemblies each include a series of segments 70 arranged in a chain-like manner. Each segment 70 includes at least one endless belt 74 trained over relatively adjacent pairs of the transversely extending drive rollers 76 which are shared with adjacent endless belts. Preferably, each segment includes a plurality of laterally spaced apart belts that alternate with the belts of an adjacent segment at the ends thereof that overlap at a shared sleeve or drive roller. The sleeve/drive roller preferably has a series of laterally spaced apart belt grooves 77 for receiving belts for proper belt tracking. The inside flights 80 of the belts define a passageway 78 for the cut strips of cushioning (not shown) exiting the conversion machine 10. As shown in Figs. 2 and 3, each drive roller 76 is rotatably supported on a shaft 82 which also functions as a link pin, the ends thereof being interconnected by laterally inner and outer links 90 and 91 at opposite sides of the assemblies 66 and 68.

[0020] Each segment 70 preferably is identical to the next adjacent segment. As a result, the same components can be used for each segment. Thus, the number of segments in each guide assembly can be easily varied by adding or subtracting segments using the same components rather than special components for a specific output chute configuration. The number of segments in the guide assemblies may be the same or different depending on the particular application. As shown, the guide assembly 68 has five segments and the segment 66 has three segments.

[0021] According to the invention in its broadest sense, the guide assemblies 66, 68 need not be powered to advance the cut sections of cushioning from the output opening of the conversion machine to a remote location. That is, the guide assemblies can simply perform a guiding function for directing the product away from the machine, while still benefitting from the universal nature of the guide assemblies which is discussed below in detail. However, preferably the guide assemblies are powered by any suitable means.

[0022] In the illustrated embodiment, as best seen in Fig. 2, a motor 92 is connected to at least one of the drive rollers 76 of each guide assembly 66, 68 by an arrangement of pulleys 96, 98, 100, 101 and a drive belt 102, preferably of the double toothed type. The motor is attached to a mounting bracket 104, which in turn is attached to the housing 20. The motor is controlled by a control system such as a motor controller 106 (which preferably is part of the overall controller for the machine). The motor controller may be configured to start and stop the motor, to have the motor run continuously, to have the motor run for a preset time after a pad enters the output chute, etc. As best shown in Fig. 2, the drive shaft 105 at the upstream end of each guide assembly 66, 68 is journalled between the mounting bracket 104 and a second mounting bracket 106 attached to the housing. The end of each drive shaft 105 extends outwardly of the bracket 104 for attachment thereto of the respective drive pulley 98, 100. Also, each drive shaft has fixed thereto, for common rotation, a respective drive roller 76 over which the belts 74 of the first upstream segment 110 are trained. As will be appreciated, rotation of the first upstream drive roller will move the belts trained thereover along their endless path, and this in turn will rotate the next adjacent drive roller which will move the belts of the next guide segment, and so on.

[0023] Preferably, the brackets 104 and 106 are attached to a front cover of the housing which can be opened to gain access to the severing assembly. Thus, the output chute will move clear when accessing the severing assembly.

[0024] As shown, the guide segments 70 of the guide assemblies 66 and 68 can be positioned such that the drive rollers 76 thereof are arranged along inner/upper and outerllower arcs 73 and 74, respectively. As above mentioned, the inner surfaces, generally denoted by 112 and 114, of the guide segments formed by the inner flights of the belts thereof define the passageway 78 therebetween. The distance between the surfaces 112 and 114 (the height of the passageway) preferably is less than the thickness of the cut section or pad passing therethrough, to sufficiently compress the pad to enable the transfer thereof from the machine outlet 14 along the passageway. After the pad passes through the passageway it is ejected, for example, into a collection container 116. To increase the distance traveled by a pad after ejection from the output chute 12, the upper and lower guide segments at the downstream exit portion 118 of passageway 78 can be spaced in a slightly converging manner, thereby reducing the height of the passageway and increasing the compression force on the pad for more positive gripping and propelling of a pad. A guide or deflector 120 also aids in increasing the distance traveled by the ejected pad, by limiting the downward pull on the pad as it is ejected. Preferably, output chute 12 is utilized for guiding a severed pad from a dunnage converter mounted below a work table through an aperture in the work table to a work platform on the table in the manner set forth, for example, in commonly assigned U.S. Patent No. 5,487,717.

[0025] The path and direction of the passageway 78 can be adjusted by changing the positions of the guide segments (that is, the angle formed therebetween). The links can then be secured or locked into place by attachment to opposed side plates 122; for example via bolts 123 which screw into threaded holes 124 (Fig. 3) in the ends 82 of the drive rollers with the bolts also serving for the attachment of links 150 (Fig. 4) to shaft 82. Although two parallel side plates would normally be used, one on each side of the rollers and links, for purposes of illustration only one side plate is shown in Fig. 1. The side plates can be provided with bolt holes andlor slots at a variety of locations for selection by the assembler, or the assembler can drill bolt holes at desired locations for a given desired shape of passageway, once determined for a particular application. Alternatively, bolts can be used to fixedly clamp the links against the ends of the shafts supporting the drive rollers by tightening the bolts in the bolt holes of the shafts (see Fig. 3), thereby eliminating the need for the side plates. As a further alternative, the segments can be left free to pivot and the downstream ends of the guide assemblies attached to a support, such as a table top, to hold the guide assemblies in a desired position.

[0026] As is preferred, the output chute 12 includes a top plate 126 and a bottom plate 128 as a guard to keep foreign objects out of the chute. The plates may have holes in them to allow for circulation of air and to let dust exit from the system. If desired an outer end plate (not shown) could be utilized to cover the outer or downstream opening defined by plates 122, 126 and 128.

[0027] As shown in greater detail in Fig. 2, the brackets 104 and 106 form part of a mounting frame 130 which further comprises cross plates 132 and 134. The cross plates 132 and 134 connect the brackets 104 and 106 together and further function, together with the brackets, to form an entry chute 138 for guiding the pads from the outlet opening of the machine to the upstream end of the guide assemblies 66 and 68. This entry chute should have a length less than the minimum length of pad produced by the machine. For example, the entry chute should be less than one foot in length, preferably less than 9 inches and more preferably less than 6 inches.

[0028] In Fig. 4, there is shown an exemplary link 150 of the type used as the innerlouter links 90, 91. The link has a pair of holes 152, 154 to allow bolts to pass through for connection to a respective shaft 82, as well as for connection to the side plate 122. The link has a pair of circular half-width portions 156, 158 which enable links to be adjustably interconnected without thereby increasing the width of a linkage. This overlapping of links can be seen in Fig. 2, and particularly at the ends of the cylindrical roller 76 in Fig. 3. The link has indented portion 160 designed to receive a backing plate 162 (Fig. 2).

[0029] Backing plates such as backing plate 162 are located in the indented portion 160 of each of the upper and lower series of links 90, 91 between every pair of drive rollers in the guide assemblies 66, 68. The backing plates provide support for the inner flight of the endless belts.

[0030] During operation of the machine 10 and output chute 12, the stock supply assembly 22 supplies the stock material to the forming assembly 36. The wire former 38 and converging conical chute 40 of the forming assembly 36 cause inward folding of the lateral edges of the sheet stock material to form a continuous crumpled strip of cushioning. The feed gears 44 of the feed assembly 42 pull the stock material downstream through the machine and also function to connect the central band of the continuous strip. As the coined strip travels downstream from the feed assembly 42 it passes through the cutting assembly 28 to the output chute 12 where it is frictionally engaged on its opposed upper and lower surfaces by the upper and lower guide assemblies 66 and 68 which transfer the pad along the passageway. Once a pad of the desired length has been produced and then severed by the severing assembly 28, the guide assemblies 66 and 68 transfer the cut pad until it is ejected from the passageway.

[0031] In Fig. 5, an alternative embodiment is shown in which an output chute 212 includes a pair of guide assemblies, each of the guide assemblies having an endless belt supported on rollers.

[0032] The chute 212 includes a motor mounting plate 216, which has a motor 218 (only its motor shaft 224 can be seen) mounted on its far side as shown in Fig. 5, by means of screws or bolts 220 which pass through motor mounting holes 222 in the motor mounting plate 216. The motor shaft 224 of the motor 218 passes through a hole 225 in the motor mounting plate 216 and has attached thereto a motor pulley 226. The motor pulley 226 is mechanically coupled to upper and lower drive pulleys 228 and 230, and to a tensioning pulley 232, all by means of a toothed belt 236. The pulleys 226, 228 and 230, and the belt 236, are arranged such that the pulleys 228 and 230 rotate in opposite directions. The pulleys 228, 230 and 232 are rotatably coupled to the motor mounting plate 216, and the belt and pulleys are enclosed by a cover 240, which is attached to the motor mounting plate 216 with spacers 242 therebetween.

[0033] It will be appreciated that alternative means of coupling the drive pulleys to the motor may be used, such as chains, gears, or a belt having notches instead of teeth.

[0034] The upper and lower drive pulleys 228 and 230 are mounted on roller end shafts (not shown) that are journalled in upper and lower bearings 244 and 246. The upper and lower bearings 244 and 246 protrude through upper and lower slots 248 and 250 in the motor mounting plate 216 and are held in place by upper and lower self-locking nuts 252 and 254.

[0035] The roller end shaft in the lower bearing 246 is coupled to a lower driven roller 258 of a lower guide assembly 260. The lower driven roller 258 drives a lower endless belt 262. The lower endless belt 262 follows a path defined by a lower array 266 of roller assemblies. The roller assemblies of the lower array 266 are each mounted to both the motor mounting plate 216 and a side mounting plate 270, as is the lower driven roller.

[0036] Similarly, an upper driven roller (not shown) has an end shaft journalled in the upper bearing 244. The upper driven roller drives an upper guide assembly 272 which has an upper endless belt 274 and an upper array 276 of roller assemblies, each of the roller assemblies being mounted to the motor mounting plate 216 and the side mounting plate 270.

[0037] Preferably, as is shown, the lower and upper endless belts 262 and 274 have a width which is substantially the same as the distance between the motor mounting plate 216 and the side mounting plate 270. This belt width reduces the likelihood of paper shreds from the cushioning conversion product being lodged under the belts and possibly causing jamming. However, it will be appreciated that belts having a lesser width could be used.

[0038] Lower and upper inner surfaces 280 and 282 are formed by the flights of the lower and upper belts 262 and 274, respectively. The lower and upper inner surfaces 280 and 282 define a passageway 284 therebetween. The distances between the lower and upper inner surfaces 280 and 282 (the height of the passageway) preferably is less than the thickness of the cut pad passing therethrough, to sufficiently compress the pad to enable transfer thereof along the passageway 284.

[0039] Each of the roller assemblies of the arrays 266 and 276 has a freely rotatable roller 290 circumscribing a roller shaft 292. Each roller shaft 292 is connected to a bearing 296 with a spacer 298 therebetween. The roller shaft 292 is typically coupled to the motor mounting plate 216 and the side plate 270 by means of a screw or hex bolt 300 which passes through a hole 302 in the plate and mates with a threaded hole in the roller shaft 292. However, one of the roller assemblies of each of the arrays 266 and 276 is coupled to the plates 216 and 270 via slots such as slot 306. The coupling via a slot allows the position of a roller assembly to be adjusted in order to control tension of the appropriate endless belt.

[0040] The upper endless belt 274 travels directly along the surfaces of the upper array 276 of roller assemblies.

[0041] However, the path of the lower belt 262 along the lower inner surface 280 involves the lower belt 262 being threaded through one or more three-roller sets 310, particularly for guiding the belt along an inside turn of a concave pathway. Each of the sets 310 has two inner surface roller assemblies 312 and one offset roller assembly 314. The lower belt 262 travels around the offset roller assembly 314 and between the offset roller assembly 314 and each of the inner surface roller assemblies. It will be appreciated that the inner surface roller assemblies 312 rotate in an opposite direction to that of the offset roller assemblies 314. This arrangement allows the lower inner surface 280 to be made up solely of the lower belt 262, avoiding intrusions of the roller assemblies into the passageway 284, which might result in jamming or other degradations of performance.

[0042] Although the illustrated embodiment uses a single belt in each of the guide assemblies, it will be appreciated that more than one belt may be employed in each of the assemblies.

[0043] Cover sections 320 and 322 are used to keep foreign objects away from the lower and upper guide assemblies 260 and 272. The cover sections 320 and 322 may slide onto the motor mounting plate 216 and the side plate 270 as is shown. It will be appreciated that alternatively or in addition the cover sections may be releasably or permanently attached to the motor mounting plate and the side mounting plate, for example by means of screws, bolts, or other fasteners, by welding, by other mechanical means, or the like.

[0044] It will be appreciated that the shape andlor the height of the passageway 284 may be adjusted by reconfiguring the mounting of the lower and upper arrays 266 and 276 of roller assemblies. It will be appreciated that the motor mounting plate and the side mounting plate may be configured to have two or more sets of mounting holes andlor slots for different passageway configurations.

[0045] Referring to Figs. 6 and 7, an alternative guide assembly 414 for a chute 412 is shown. The chute 412 would have two such guide assemblies, although only one is shown. The guide assembly 414 includes a series of segments 416 arranged in a chain-like manner. Each of the segments 416 includes a pair of rollers 420 and a belt 424. The rollers are rotationally coupled to side plates 428 via shafts 430 which fit in bearings 432. The belts 424 preferably extend over substantially the entire width of the rollers 420 between the side plates 428.

[0046] One of the rollers 420 is driven by a motor 436. Rotational force is transferred successively along the segments 416 by rotation transfer mechanisms 440, which mechanically couple one of the rollers 420 of one of the segments 416 with a roller of the next segment.

[0047] As shown in the illustrated embodiment, the transfer mechanism is preferably located outside of the side plates 428. The transfer mechanism 440 includes shaft extensions 442 coupled by a transfer belt 444. Movement of one of the shaft extensions 442 results in movement of the transfer belt 444 which causes movement of the other of the shaft extensions 442. The transfer belt 444 may have grooves, teeth, notches, or the like thereupon to improve the grip between the transfer belt 444 and the shaft extensions 442. Likewise, the shaft extensions 442 may have structures or surface treatments thereupon to improve the grip between the transfer belt 444 and the shaft extensions 442.

[0048] It will be appreciated that the two guide assemblies of the chute 412 may be suitably arrayed to create a passage therebetween for transporting a cushioning conversion product such as a pad, in a manner similar to that described for the embodiments shown in Figs. 1-5. It will further be appreciated that the guide assemblies of the chute 412 may be reconfigured to adjust the size and shape of the passageway, in a manner similar to that for the embodiment shown in Fig. 5 and described above.

[0049] Although the shafts 430 and shaft extensions 442 are herein separately referenced, it will be appreciated each of the shaft - shaft extension combinations may be formed as a single piece. It will further be appreciated that the shaft extensions may have a different diameter than the shafts.

[0050] Although the rotation transfer mechanism is illustrated as involving a belt coupling two shaft extensions, it will be appreciated that other rotation transfer mechanisms may be employed. For example, a chain may be used to couple appropriate shaft extensions. Alternatively, spur gears or helical gears may be used to rotationally couple a roller of one module to a roller of the next module. Alternatively andlor in addition, a roller may be interposed between the shaft extensions.

[0051] Referring to Fig. 8, a portion of a modified guide assembly 614, is shown. The guide assembly 614 has segments 616 and 618 which overlap so as to reduce the likelihood that a pad or other cushioning conversion machine output 620 may be drawn into a gap 622 between the modules 616 and 618.

[0052] A roller 626 of the downstream module 618 is located further upstream (downward as shown in Fig. 8) when compared to location 628, which is the location the roller would be at if there was no "overlap" of the downstream module 618 by the upstream module 616. Overlapping of the modules by offsetting the roller 626 of the downstream module 618 in an upstream direction makes it less likely for the pad 620 to be drawn into the gap 622 between the modules 616 and 618. Thus as the pad 620 moves in a downstream direction 632 it contacts the module 618 at a point further form the roller 626 than it would for a roller at the location 628.

[0053] It will be appreciated that the guide assembly 614 may be suitably arrayed with another similar guide assembly to form a chute with a passage therebetween for transporting a cushioning conversion product such as a pad, in a manner similar to that described for the embodiments shown in Figs. 1-7. It will further be appreciated that these guide assemblies may be coupled to plates so as to be reconfigurable to adjust the size and shape of the passageway, in a manner similar to that for the embodiments shown in Figs. 5-7 and described above.

[0054] Although the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components, the terms (including a reference to a "means") used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of the several 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.

Claims

1. A cushioning conversion system comprising:

a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and

an output chute including first and second series of drive elements spaced to form therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, each of the first and second series of drive elements being adjustably interconnected for varying the path of the passageway.

2. The system of claim 1 wherein the series of drive elements comprise cylindrical rollers connected by a plurality of endless belts.

3. The system of claim 2 wherein the endless belts extend across substantially the entire width of the drive rollers.

4. The system of claim 2, further comprising a plurality of links connected to the cylindrical rollers, the links adjustably interconnected to form first and second articulated linkages corresponding to the first and second series of drive elements, respectively.

5. The system of claim 4, further comprising a plurality of backing plates, each backing plate attached to at least one of the links, the backing plates located along the passageway to support the endless belts.

6. The system of claim 5, wherein the cylindrical rollers have internally threaded holes, and further comprising a first side plate with holes therein through which a plurality of bolts can be installed to secure the rollers.

7. The system of claim 6, further comprising a second side plate and top and bottom covers, the top and bottom covers each having openings therein.

8. The system of claim 5, wherein the cylindrical rollers have internally threaded holes, and the links have holes therein aligned with the threaded holes, and further comprising bolts which can be passed through the holes in the links and tightened in the threaded holes to clamp the links in place.

9. The system of claim 1, wherein the first and second series of drive elements rotate in opposite directions.

10. The system of claim 1, wherein the first and second series of drive elements compress the pad.

11. The system of claim 10 wherein the passageway has an exit portion wherein the drive elements are situated to reduce the height of the passageway, thereby further compressing the pad.

12. The system of claim 1, further comprising a device for rotatably driving the drive elements.

13. The system of claim 12, wherein the device for rotatably driving the drive elements is a motor.

14. The system of claim 13, further comprising a control system for starting and stopping the motor.

15. A cushioning conversion system comprising:

a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and

an output chute including first and second guide assemblies being spaced apart to define therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, the first and second driving assemblies having first and second driving surfaces, respectively, the driving surfaces being adjustable to vary the path of the passageway.

16. The system of claim 15, wherein the first guide assembly comprises a plurality of drive elements with drive surfaces, the first driving surface consisting of portions of the drive surfaces of the drive elements.

17. The system of claim 16, wherein the drive elements comprise cylindrical rollers and endless belts.

18. The system of claim 15, wherein the first and second guide assemblies each comprise a plurality of drive elements with drive surfaces, the first and second driving surfaces consisting of portions of the drive surfaces of the drive elements.

19. The system of claim 18, wherein the drive elements comprise cylindrical rollers and endless belts.

20. A cushioning conversion system comprising:

a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and

an output chute including first and second series of articulated guide segments forming therebetween a passageway for the cushioning product, each of the first and second series of guide segments being adjustably interconnected for varying the path of the passageway.

21. A system as set forth in claim 20, where the guide segments are composed of side links and at least one roller extending between said side links.

22. A cushioning conversion system comprising:

a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine;

means for transporting the cushioning product along a passageway; and

means for adjusting the shape of the passageway.

23. A cushioning conversion system comprising:

a cushioning conversion machine for converting sheet stock material into a cushioning product, the conversion machine having an outlet through which the cushioning product exits the machine; and

an output chute including first and second drive elements spaced to form therebetween a passageway for the cushioning product and to effect the transfer of the cushioning product along the passageway, each of the first and second drive elements being adjustably interconnected for varying the path of the passageway.

24. The system of claim 23 wherein the drive elements each includes an array of rollers and an endless belt.

25. The system of claim 24 wherein each of the endless belts has substantially the same width as the rollers.

26. The system of claim 1 wherein the drive elements are mechanically coupled by transfer mechanisms.

27. The system of claim 26 wherein the transfer mechanisms each include a pair of shaft extensions, each of the shaft extensions coupled to one of the drive elements, and a transfer belt coupled to each of the shaft extensions.

28. The system of claim 1, wherein the drive elements of each series overlap with upstream modules overlapping downstream modules.

Drawing