Note: Descriptions are shown in the official language in which they were submitted.
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MACHINE FOR CONVERTING STOCK MATERIAL INTO A CUSHIONING PRODUCT
The herein described invention relates generally to a cushioning conversion
machine and method for converting sheet-like stock material into a cushioning product,
and a resultant novel cushioning product.
In the process of shipping an item from one location to another, a protective
packaging material is typically placed in the shipping case, or box, to fill any voids
and/or to cushion the item during the shipping process. Some conventional protective
10 packaging materials are plastic foam peanuts and plastic bubble pack. While these
conventional plastic materials seem to adequately perform as cushioning products, they
are not without disadvantages. Perhaps the most serious drawback of plastic bubble
wrap and/or plastic foam peanuts is their effect on our environment. Quite simply,
these plastic packaging materials are not biodegradable and thus they cannot avoid
15 further multiplying our planet's already critical waste disposal problems. The non-
biodegradability of these packaging materials has become increasingly i",po, Lant in light
of many industries adopting more progressive policies in terms of environmental
responsibility.
The foregoing and other disadvantages of conventional plastic packaging
20 materials have made paper protective packaging material a very popular alterative.
Paper is biodegradable, recyclable and renewable, making it an environmentally respons-
ible choice for conscientious industries.
While paper in sheet form could possibly be used as a protective packaging
material, it is usually preferable to convert the sheets of paper into a relatively low
25 density pad-like cushioning dunnage product. This conversion may be accomplished by
a cushioning conversion machine/method, such as those disclosed in U.S. Patent Nos.
3,509,798,3,603,216,3,655,500,3,779,039,4,026,198,4,109,040,4,717,613
and 4,750,896, and also in pending U.S. Patent Applications Nos. 07/533,755,
07/538,181,07/592,572,07/734,512,07/786,573,07/840,306 and 07/861,225.
With most, if not all, of the conversion machines/methods disclosed in the
above-identified patents and applications, the cushioning product is created by
converting multi-layer, and preferably three-layer, paper stock material into a desired
geometry. The cushioning product includes pillow-like portions formed by the lateral
edges of all of the layers of stock paper being rolled inwardly to form a pair of twin
35 spirals. The central regions of this structure are then compressed and connected (such
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as by coining) to form a central compressed portion and two lateral pillow-like portions
which essentially account for the cushioning qualities of the product.
The central compressed portion of such a cushioning product is believed to be
necessary to ensure that the pillow-like portions optimally maintain their cushioning
qualities. In other words, without a connection of this type, the resiliency of the pillow-
like portions would encourage the twin spirals to "unwind." However, the centralportion, due to its compressed state, increases the density of the overall cushioning
product.
In the past, attempts have been made to decrease the density of the cushioning
10 products by altering its construction. Specifically, U.S. Patent No. 4,717,613
introduced a conversion process/machine which creates a lower density cushioningproduct. The decrease in density is accomplished by urging the stock material
outwardly into the pillow-like portions whereby the central compressed section is
comprised of a lesser amount of stock material.
Despite past improvements, a need remains for conversion machines/methods
which create paper cushioning products of even lower densities. Moreover, irrespective
of particular density properties, environmental and other concerns provide a constant
desire for new and effective paper cushioning products and for machines/methods for
creating such products.
The present invention provides a cushioning conversion machine and method for
converting multiple layer of sheet-like stock material into a cushioning product. The
construction of the cushioning product is such that the product's overall density is
relatively low while at the same time the integrity of the product's cushioning qualities
are maintained. Moreover, the cushioning product of the present invention may be, and
25 preferably is, made of paper which is biodegradable, recyclable and renewable.
Accordingly, the present invention provides an environmentally responsible alternative
to plastic packaging products.
In accordance with broad aspects of the invention, cushioning conversion
machines and methods are provided for converting plural layers of a sheet-like stock
30 material into a dunnage product.
According to one broad aspect of the invention, a machine/method includes an
assembly/step in which plural layers of the stock material are shaped into a three-
dimensional strip of dunnage. In the strip of dunnage, at least a first layer of the stock
material has overlapped edge portions which are generally coplanar with adjacent35 unoverlapped portions of the first layer. The machine/method also includes an
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assembly/step in which the overlapped layers of the first layer are connected together
separate from a central portion of the first layer.
According to another broad aspect of the invention, a machine/method includes
a first shaping device/step, a second shaping device/step, a connecting assembly/step,
5 and an inner feed assembly/step. The first shaping device/step shapes a first layer of
the stock material into a casing with its lateral edge portions being brought into
overlapping relationship one inside the other. The second shaping device/step shapes
at least a second layer of the stock material into a stuffing for the casing. The
connecting assembly/device is positioned/performed downstream of the first shaping
10 device/step and connects the overlapped portions of the first layer. The inner feed
assembly/step is positioned/performed downstream of the second shaping device/step
and feeds the second layer into the interior of the casing.
According to another broad aspect of the invention, a machine/method includes
a forming assembly/step, a connecting assembly/step, and a guiding device/step. The
15 forming assembly/step shapes the plural layers of the stock material into a three-
dimensional strip of dunnage having central portions and overlapped edge portions. The
connecting assembly/step is positioned/performed downstream of the for".i"~
assembly/step and connects the overlapped lateral edge portions of the layers
separately from the central portions of the layers. The guiding device/step directs the
20 central portions of the layers away from the connecting assembly to prevent the central
portions from passing through the connecting assembiy.
One particular cushioning conversion machine according to the present invention
includes a first shaping device which shapes a first layer of the stock material into a
casing with the lateral edge portions being brought into overlapping relationship one
25 inside the other, a second shaping device which shapes at least one second layer of the
stock material into a stuffing for the for the casing, a connecting assembly downstream
of the first shaping device for connecting the overlapped lateral edge portions of the
first layer separate from the stuffing, and an inner feed assembly downstream of the
second shaping device for feeding the second layer into the interior of the casing. The
30 machine further comprises an outer feed assembly for engaging and feeding a central
portion of the first layer, the outer and connecting assemblies being cooperative to pull
the first layer through the first shaping device. The outer feed assembly and the
connecting assembly engage the first layer at transversely aligned locations relative to a
movement path of the first layer. The connecting assembly includes a pair of rotating
35 connecting members forming therebetween a nip through which the overlapped lateral
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edge portions of the first layer pass, the outer feed assembly includes a pair of rotali,.g
feed members forming therebetween a nip through which the central portion of the first
layer passes, and the inner feed assembly includes a pair of rotating crumpling members
forming therebetween a nip though which the second layer or layers pass and are
5 crumpled thereby. The rotating crumpling members of the inner feed assembly are
mounted to downstream ends of respective supports attached in cantilever-like manner
to a frame structure of the machine. The supports respectively extend on opposite
sides of the second shaping device from an upstream end of the first shaping device to
a downstream end of the first shaping device, and an inner one of the IOtdlillg
10 connecting members of the connecting assembly and an inner one of the rotating feed
members of the outer feed assembly are respectively mounted to the downstream ends
of the supports. The rotating crumpling members of the inner feed assembly are driven
by the rotating members of either the outer or connecting assemblies, which have the
outer rotating member thereof driven by a feed motor. An outer one of the rotating
15 connecting members or an outer one of the rotdling feed members is mounted to the
frame for movement transversely to the path of the stock material. The outer
connecting or feed member is resiliently biased towards the inner connecting or feed
member for resiliently constraining the downstream end of a respective one of the
supports against movement away from the downstream end of the other support,
20 whereby one of the rotating crumpling members of the inner feed assembly will be
resiliently constrained against movement away from the other crumpling member. The
first shaping device includes a folding device having converging side walls and
respective wings inwardly turned toward one another, the wings being overlapped and
spaced apart. An outer one of the overlapped wings defines with an inner one of the
25 wings a first area for receiving one edge portion of the first layer of stock material, and
the second shaping device has a surface defining with the inner one of the wings a
second area for receiving an opposite edge portion of the first layer. The folding device
further includes an inner folder surface and an outer center guide surface extending
laterally between the side wall and defining therebetween a passage for the central
30 portion of the first layer, and the inner folder surface has side edges spaced from the
side walls. There is provided at least one roller which holds the first layer against an
upstream end portion of the inner folder surface and edge guides extending generally
perpendicular to the inner folder surface and spaced from the side edges of the inner
folder surface at a location downstream of the upstream end portion of the inner folder
35 surface and upstream of the side walls of the folding device. The second shaping
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device includes a converging chute and a former which cooperaLe to turn inwardly the
edges of the second layer to form a pillow-like stuffing. The converging chute may be
mounted between the aforesaid cantilevered supports.
Another particular cushioning conversion machine according to the present
5 invention comprises a forming assembly which shapes plural layers of the stock material
into a continuous three dimensional strip of dunnage having central portions andoverlapped edge portions, a connecting assembly downstream of the forming assembly
for connecting the overlapped lateral edge portions of the layers separately from central
portions of the layers, and a guide which directs the central portions of the layers away
10 from connecting assembly to prevent the central portions from passing through the
connecting assembly. The connecting assembly includes a pair of rotating connecting
members forming therebetween a nip through which the overlapped lateral edge
portions of the first layer pass. The machine a frame structure and the forming
assembly includes a chute and a former extending into the chute with one rotating
15 member being mounted to a downstream end of the former interiorly of the path of the
stock material and the other which is ,olaLably driven being mounted to the frame
structure independently of the former and externally of the path of the stock material.
More particularly the one rotaLi"g member is mounted to a downstream end of a
bracket connected to the former in cantilever-like manner and projecting through and
20 beyond a downstream end of the chute. Moreover the guide includes a finger
projecting forwardly from the former to a point at least partially overlapping the rotaLi"y
connecting members relative to the movement path of the stock material through the
machine.
Also accordi"g to broad aspects of the invention cushian;.,g products are
25 provided.
Accordi,lg to one broad aspect a cushioning product co~ es plural layers of
sheet-like stock material folded upon themselves. At least an outer layer of the plural
layers has lateral edge portions overlapped and connected together separate from a
central portion of the outer layer. The overlapped lateral edge portions of the outer layer
30 are generally coplanar with adjacent unove~lapped portions of the outer layer.
According to another broad aspect a cushioning product co",p,i:,es plural layers of
sheet-like stock material folded upon themselves. An outer layer of the plural layers has
lateral edge portions overlapped and connected togell,er separate from a central portion
of the outer layer. The remaining inner layers of the plural layers also have lateral end
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portions overlapped and connected together separ~le from their .~spe.,1i~/e central
portions.
According to another broad aspect, a cushioning product cG",p,i~es plural layers of
sheet-like stock ~ale~ial folded upon ll,el"selves. An outer layer of the plural layers has
lateral edge po,lions overlapped and connected together separ~le from a central portion
of the outer layer. The remaining inner layers of the plural layers also have lateral end
portions overlapped and connected together with the overlapped lateral edge portions of
the outer layer.
In any of these machines, methods, or products, the plural layers of stock material
10 may co"",,i:.e biodeyl ~ e~ recyclable, and reus~~ le Kraft paper.
The foregoing and other features of the invention are hereinafter fully described
and particularly pointed out in the claims, the following desc,i~,Lion and annexed
drawings setting forth in detail a certain illustrative embodiment of the invention, this
embodiment being indicative, however, of but one of the various ways in which the
15 principles of the invention may be employed.
Figure 1 is a side view of a cushioning conversion machine according to the
invention with the side wall of the machine's housing nearest the viewer broken away
to permit viewing of internal machine components.
Figure 2 is a plan view of the conversion machine with the wall of the housing
20 nearest the viewer broken away to permit viewing of internal machine components.
Figures 3-6 are sectional views of the machine of Figure 1 respectively taken
along the lines 3-3, 4-4, 5-5 and 6-6 of Figure 1.
Figure 7 is an enlarged fragmentary portion of Figure 1.
Figure 8 is a schematic perspective view of a cushioning product according to
25 the present invention.
Figure 9 is a side view of another cushioning conversion machine according to
the invention with a side panel of the machine's housing nearest the viewer removed to
permit viewing of internal machine components.
Figure 10 is a partial plan view of the conversion machine with the top panel of30 the housing partly broken away to permit viewing of internal machine components.
Figure 11 is a plan view of the modified former used in the machine of Figure 9.Figure 12 is a side view of the modified former used in the machine of Figure 9.Figure 13 is a front end view of the modified former used in the machine of
Figure 9.
Figure 14 is a plan view of the modified chute used in the machine of Figure 9.
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Figure 15 is a side view of the modified chute used in the machine of Figure 9.
Figure 16 is a front end view of the modified chute used in the machine of Figure
9.
Figure 17 is a sectional view through the ~LiLchi~lg gears used in the machine of
5 Figure 9.
Figure 18 is a side view of the stitching gears used in the machine of Figure 9.Figure 19 is a schematic illustration of another cushioning product according tothe invention.
Figure 20 is a cross-sectional view taken along the line 20-20 of Figure 19.
Referring now to Figures 1 and 2, an exemplary embodiment of a cushioning
convers~ion machine according to the invention is designated generally by reference
numeral 30. The machine includes a housing 31 which forms the structural skeleton for
the conversion assemblies of the machine 30. The conversion assemblies include astock supply assembly 32, a forming assembly 33 composed of an outer shapi.lg
15 assembly 34 and an inner sh~, ..lg assembly 35, feed assemblies 36 powered by a feed
motor 37, a cutting assembly 38 powered by a cut motor 39, and a post-cutting
con~llaillill~ assembly 40. These assemblies of the machine 30 cooperate to convert
sheet-like stock material into a cushioning product according to the present invention.
The roles the conversion assemblies and components thereof play in the creation of
20 such a cushioning product are explained below in detail. In regard to the various
functions performed by the noted assemblies and components thereof, the terms
(including a reference to a "means") used to identify the herein-described assemblies
and devices are intended to correspond, unless otherwise indicated, to any
assembly/device which performs the specified function of such an assembly/device,
25 that is functionally equivalent even though not structurally equivalent to the disclosed
structure which performs the function in the illustrated exemplary embodiment of the
invention .
The illustrated machine 30, representing a preferred embodiment of the
invention, is designed to convert multi-layer stock material into a cushioning product.
30 Preferably, the stock material comprises at least two and preferably three or more
superimposed layers which may be supplied in the form of a stock roll. These layers
are each preferably 27-30 inches wide, and comprised of biodegradable, recyclable and
reusable 30-50 pound Kraft paper.
The housing 31 includes a base plate or wall 42, side plates or walls 44, and an35 end plate or wall 46 which collectively form a frame structure to which the conversion
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assemblies of the machine are mounted. The base wall 42 is generally planar and
rectangular in shape. The housing also includes a top wall 45, which together with the
base, side and end walls, form an enclosure. All or a part of the top wall may be in the
form of an openable cover for permitting easy access to the components of the
5 machine located inside the housing. As shown in Figure 2, the motors 37 and 39 are
mounted on the base wall 42 which may be provided with a transverse mounting plate
47 which forms part of the base wall or plate 42. The motors are disposed on opposite
sides of the forming assembly 33.
The end plate 46 extends perpendicularly from a location near, but inward from,
10 the downstream end of the base wall 42. It should be noted that the terms "upstream"
and "downstream" are herein used in relation to the direction of flow of the stock
material through the machine 30. The end plate 46 is generally rectangular and planar
and includes a dunnage outlet opening. The housing (or frame) 31 also includes a front
cover or plate 49 which extends perpendicularly from the downstream edge of the base
15 wall 42. Thus, the end plate 46 and front plate 49 bound upstream and downstream
ends of a box-like extended portion of the downstream end of the housing 31. Thefront plate 49 may be a door-like structure which may be selectively opened to access
cutting assembly components of the cutting assembly 38. The post cutting con~l,ainl
40 may be mounted to the front plate 49 and includes a tubular portion generally20 corresponding in cross-section to the cushioning product produced by the machine.
The base and side walls 42 and 44 have at the upstream end of the housing 31
inturned edge portions that form a rectangular border around a centrally located, and
relatively large, rectangular stock inlet opening 51. This border may be viewed as an
end plate or wall extending perpendicularly from the upstream edge of the base wall 42
25 and to which the stock supply assembly 32 is attached.
The illustrated stock supply assembly 32, thus located at the rear or upstream
end (to the left in Figures 1 and 2) of the machine 30, includes a holder assembly 54
for a stock roll 55. The illustrated stock roll consists of three superimposed plies or
layers 56-58 of biodegradable, recyclable and reusable thirty-pound Kraft paper rolled
30 onto a hollow cylindrical tube. The stock roll may be supported by a spindle 60 or
other stock roll holder device, such as that shown in U.S. Patent Application No.
08/267,960between the lower ends of a pair of hanger brackets 61 provided, as
shown, with slots 62 for receiving the ends of the spindle. The illu-~;l,ated hanger
brackets 61 (or hangers) have a double L or stepped configuration for use with the
35 machine 30 when supported in a horizontal orientation as shown. It will be appreciated
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that the machine 30 may be otherwise oriented, such as vertically or at an incline, for
different appiications. Also, the stock roll holder assembly 54 need not be mounted to
the machine housing as shown, but instead may be separate from the machine housing
as in the form of a cart, especially when large and thus heavy stock rolls are used.
The upper risers or legs 63 of the stock roll hangers 61 are secured to the rearwall of the housing 31. The intermediate legs 64 extend horizontally away from the
housing and the lower legs 65 depend from the outer ends of the intermediate legs.
The hangers have journalled therebetween guide rollers 67 and 68 over which the
superimposed layers of stock material are trained. Between the stock roll 55 and first
guide roller 67, the superimposed layers of stock material are passed around a damper
roller 70 which is biased to exert a tensioning force on the stock material being fed into
the machine. In the illustrated embodiment, the damper roller is journalled between the
ends of pivot arms 71 pivotally attached at 72 to the hangers 61, and the damper roller
is biased by gravity, although other biasing a~ange~ents may be used such as resilient
spring biasing means. The dancer roller pivots about the pivot 72 of the pivot arms as
the tension on the stock material is increased or decreased during unwinding of the
stock material from the stock roll. This pivoting action, combined with the serpentine
path determined by the guide rollers 67 and 68, dampens the effects of starting and
stopping of the stock material feed mechanisms ~hereinafter described) and thereby
assists in maintaining a more uniform tension on the stock material.
From the guide roller 68, one layer 56 of the stock material, herein also referred
to as an outer or first layer, passes to the entry or upstream end of the outer shaping
assembly or device 34. The other layer or layers 57 and 58 of stock material, herein
also referred to as an inner or second layer or layers, passes to separators 75-77 which
separate the plies from one another. As shown, the separators are rollers journalled
between the upper legs 63 of the hangers 61. From the separators, the inner layers
pass to the entry end of the inner shaping assembly 33.
The inner shaping assembly shapes the inner layers of stock material into a
stuffing for a tubular casing as the inner layers are fed through the inner shaping
assembly by an inner feed assembly 80 that constitutes one of the aforesaid feedassemblies. In the illustrated embodiment the inner feed assembly is located
downstream of the inner shaping assembly and thus pulls the inner layer through the
interior of the inner shaping assembly.
With reference to Figures 1, 2, 4 and 5, the inner shaping assembly 33 includes
a shaping chute 82 and a former 83 which cooperate to turn inwardly the edges of the
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inner layers to form a strip of pillow-like stuffing. The illustrated shaping chute (a
converging chute as the cross section of the chute progressively decreases) and former
are of the type shown in U.S. Patent Application No. 08/386,355. As will be
appreciated, the converging chute has side walls which turn towards one another to roll
lateral edge portions of the inner layers toward one another. In addition to this rolling
action, the inner layers will crumple because of the progressively decreasing cross-
section of the converging chute. The former 83 is in the form of a hair pin with one leg
extending generally parallel with a center guide wall of the converging chute to define a
relatively narrow guide channel for the center portion of the inner layers moving through
the converging chute, whereby the center portion is held in close proximity to said
center guide wall. The other leg of the hair pin is attached to the wall of the chute
opposite the center guide wall and the former preferably has a rounded upstream end as
shown in Figure 1 for providing a smooth guide-in for the center portion of the inner
layers.
The chute 82 is mounted between a pair of supports 90 and 91 herein referred
to as the upper and lower supports in view of their relative positions shown in the
drawings and not to limit the machine to a hori~onlal orientation. As best shown in
Figures 1 and 3, the upper support 90 is attached at its upstream end in cantilever-like
manner to a short post 92 on a transverse frame member 94 extending between the
side walls 44 of the housing 31. The lower support 91 is similarly attached at its
upstream end in cantilever-like manner to a short post 96 secured to the bottom wall 42
of the housing. From their respective points of attachment, the cantilevered supports
extend downstream in generally parallel, but slightly converging, relationship as shown
in Figure 1. The chute may be attached on opposite sides thereof (top and bottom in
Figure 1 ) to the upper and lower supports. Looking at Figure 1, it will be appreciated
that the transverse frame member 94 is offset from the path of the inner layers 57 and
58 from the separators 75-77 to the inner shaping assembly 33. For increased
stiffness and strength, the supports preferably are fabricated as U-shape channel
members having outwardly turned ears at the ends of the legs of the channel, as best
shown in Figure 5. The outwardly turned ears may provide for attachment to another
member in the case of the upper support or may cooperate to form part of a guidesurface for a layer of stock material passing thereover in the case of the lower support.
For feeding the inner layers through the inner shaping assembly 33, the inner
feed assembly, as best shown in Figures 6 and 7, includes a pair of rotating crumpling
members 100 and 101 forming therebetween a nip through which a central region or
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band of the strip of stuffing formed from the inner layers pass and which is further
crumpled and preferably loosely connected. The crumpling members prererably are
toothed gear-like members similar to the gear-like members shown in U.S. Patent No.
4,750,896. The crumpling members are mounted for rotation by shafts 102 and 103
5 extending between clevis-like extensions 104 and 105 at the downstream ends of the
~ supports 90 and 91. As described further below, at least one of the crumpling
members is rotatably driven, in this case the crumpling member 100. The supports hold
the crumpling members with the teeth thereof in loosely meshed relationship for
crumpling and loosely connecting the inner layers passing therebetween. As is
preferred, the inner layers are loosely connected such that they can separate somewhat
within the tubular casing formed therearound in the hereinafter described manner. This
adds to the loft or reduced density of the finished cushioning or dunnage product.
Because of the length and an inherent resilient flexibility of the cantilever
supports 90 and 91 (and the chute 82 which may be d;sposed therebetween), the
crumpling members 100 and :101 are free to float towards and away from one another
to accommodate different thicknesses of stock material between the crumpling
members. r~aferably, the amount of squeeze pressure applied by the crumpling
members is adjustably controlled in the manner herei"arler described in connection with
the outer shaping assembly to obtain a desired crumpling and loose connecting action.
Referring now to Figures 1-5, the outer shaping assembly 34 shapes the outer
layer of the stock material into a tubular casing with the lateral edge portions being
brought into overlapping relationship as the outer layer is fed through the outer shaping
assembly by outer feed assemblies 108 and 109. In the illustrated embodiment theouter feed assemblies are located downstream of the outer shaping assembly and thus
pull the outer layer through the interior of the outer shaping assembly. The outer
shaping assembly includes a folding device 11 0 including an outer folding channel 111
and an inner folding plate 112 extending into the folding channel. The folding channel
has converging side walls 1 13 and 1 14 depending from a laterally extending guide wall
115 which together form an inverted U-shape as best seen in Figure 5.
The folding plate 112 has a rounded upstream or entry end over which the
central region of the outer layer passes. The upstream end of the inner folding plate is
narrower than the width of the outer layer such that lateral edge portions of the outer
layer overhang the sides of the folding plate. From its upstream end the folding plate
tapers to its narrower downstream end which has a width greater than the width of the
downstream end of the converging chute 82 as best shown in Figure 2. Also, the
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12
upstream end of the inner folding plate has a width less than the width of the
downstream end of the folding channel such that the edges of the folder plate are
spaced from the adjacent side walls 1 13 and 1 14 of the folding channel 1 1 1.
The outer layer is held against the rounded entry end of the folding plate 1 12 by
5 a folder roller or rollers 118 which, in the illustrated embodiment, are held by gravity
against the folding plate. As shown, two rollers are rotatably mounted on an axle or
shaft 119 which extends transversely between the free ends of a pair of pivot arms
120. The pivot arms have their other ends pivotally connected to a transverse member
122 extending between the side walls 44 of the machine housing 31. This
10 arrangement enables the folder rollers to be easily lifted clear of the inner folding plate
to facilitate threading of the outer layer therebetween during loading on the machine.
The folder roller or rollers 1 18 preferdbly have annular flanges 124 (Figures 2and 3) at the outer sides thereof which overhang respective side edges of the folder
plate 112 for urging downwardly the lateral edge portions of the outer layer
15 overhanging the folder plate. Further downward urging or foiding of the lateral edge
portions is effected by edge guides 126 (Figures 1, 2 and 4) extending generallyperpendicularly to the folder plate and spaced from respective side edges of said folder
plate at a location downstream of the upstream end portion of the folder plate and
upstream of the side walls 1 13 and 1 14 of the folding channel 1 1 1. The edge guides,
20 preferably rollers, assist in guiding the edge portions of the outer layer inwardly of the
side walls of the folding channel while the central region of the outer layer is guided
between the outer surface of the folder plate 112 and inner surface of the guide wall
115 of the folding channel, which guide wall preferably has an upstream extension
extending to approximately the upstream end of the folder plate as best shown in Figure
25 1. As also shown in Figure 1, the guide wall and folder plate preferably converge
towards one another going form their upstream to their downstream ends.
The side walls 1 13 and 1 14 of the folding channel 1 1 1 have along their edgesopposite the guide wall 1 15 respective wings 130 and 131 inwardly turned toward one
another as best shown in Figures 1, 2 and 5. The wings, which are triangular in shape,
30 have the downstream ends thereof overlapped (see the broken line profile in Figure 2)
and spaced apart IFigures 1 and 5). The outer one 131 of the overlapped wings defines
with the inner one 130 of said wings a first area for receiving one folded under edge
portion of the outer layer of stock material, and the inner one of the wings defines with
an outer surface of the shaping chute 82 a second area for receiving an opposite edge
35 portion of the outer layer. Preferably, the wings converge toward the inner folder plate
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and guide wall. As the outer layer passes through the folding device, the outer lateral
edge portions of the outer layer are folded in upon themselves to form a tubular casing
surrounding the strip of stuffing exiting from the inner feed assembly.
For feeding the outer layer through the outer shaping assembly 34, the outer
feed assembly 108, as best shown in Figures 6 and 7, includes a pair of roLdlin9 feed
members 134 and 135 forming therebetween a nip through which a central region ofthe outer layer passes. The lotdlillg feed members 134 and 135 prererdbly are toothed
gear-like members similar to the gear-like members shown in U.S. Patent No.
4,750,896. The inner rotdLi"g feed member 135 is mounted for rotation by a shaft 137
10 extending between the ears of the adjacent clevis-like extension 104 at the downstream
end of the cantiievered support 90. The outer roLd~i"g feed member 134 is mounted to
a shaft 138 which has the ends thereof supported in laterally spaced apart pillow blocks
140 which, if desired, may be joined together, as such by a laterally extending member,
for uniform translating movement. The pillow block housings 140 are secured to the
15 front plate 46 of the housing 31 by fasteners such as bolts 142 guided in respective
slots 144 extending perpendicular to the path of the outer layer between the rOtdlin9
feed members. Accordingly, the outer rotdLi"g feed member is movable transversely to
the path of the outer layer. Each pillow block (bearing~ housings, and thus the outer
rotating feed member, is biased inwardly toward the inner rolali"g feed member by
20 suitable resilient biasin~ means such as a spring 146 attached between the bearing
housing and conrlunLil-g housing structure as illualldled in Figures 6 and 7. As will be
appreciated, the resilient biasing force acts through the meshing rotating feed members
134 and 135 to resiliently coll lldin outward flexing of the free end of the cantilevered
support 90 and thus the respective rot~liug crumpling member 100.
The outer rotating feed member 134 is driven by the feed motor 37 (Figure 1) in
well known manner using a suitable drive train, which may include for example a chain
148 trained around a sprocket 149 on the shaft 138 and a driven sprocket 150, with a
suitable resiliently biased take-up device (not shown) being used to take-up play in the
chain that arises from movement of the shaft sprocket 149 relative to the driven30 sprocket 150. The outer rotating feed member 134 will rotatably drive the inner
rotating feed member 135. The inner I~JLdlin9 feed member 135 is also meshed with
the relatively adjacent one of the crumpling members 100 of the inner feed assembly
80 whereby such crumpling member will be rotatably driven synchronously with theouter feed assembly for feeding of the inner layers.
CA 022234l3 l997-l2-03
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The other outer feed assembly 109 is similar to the feed assembly 108, but is
referred to herein as the connecting assembly because it functions to connect together
the overlapped lateral edge portions of the outer layer. The connecting assembly 109
includes a pair of rotating connecting members 155 and 156 forming therebetween a
5 nip through which the overlapped lateral edge portions of the outer layer pass. The
rotating connecting members preferably are toothed gear-like members of the typedescribed in commonly assigned U.S. Patent No. 4,968,291, or any other pair of
rotating devices that provide for secure sLilchil)g together of the outer layer edge
portions. The gear-like members or gears shown in this patent operate to perforate or
10 coin the overlapped lateral edge portions along a central band. Although not required or
necessary desired for the rotdling members of the other feed assemblies, the
connecting members 155 and 156 operdle to provide a secure mechanical interference
interlock between the overlapped lateral edge portions of the outer layer to form a
connected tubular casing for the stuffing that has substantial holding resialance to
15 "unzippering" of the thus formed stitched seam.
The inner rOldlill9 connecting member 156 is mounted for rotation by a shaft
158 extending between the ears of the adjacent clevis-like extension 105 at the
downstream end of the cantilevered support 91. The outer ruldli,lg connecting member
155 is mounted to a shaft 159 which has the ends thereof supported in laterally spaced
20 apart bearing housings 160. The bearing housings are essentially the same as the
above described bearing housings 140 and are similarly mounted to the front plate 46
by bolts 161 guided in respective slots 162 extending perpendicular to the path of the
outer layer between the rotating connecting members. Each bearing housing 160 isbiased inwardly toward the inner rotating connecting member by a spring 164. As will
25 be appreciated, the resilient biasing of the spring forces acts through the meshing
rotating connecting members 155 and 156 to resiliently constrain outward flexing of
the free end of the cantilevered support 91 and thus the respective rotating crumpling
member 101. Thus, the free ends of both cantilevered supports 90 and 91 are
resiliently constrained against outward flexing. However, it will be appreciated that
30 such resilient constraint may also be effected even if the bearing mounts for one of the
shafts 138 and 159 is fixed against movement relative to the frame. The amount of
squeeze pressure applied by the crumpling members is adjustably controlled by
adjusting the biasing force of the springs 146 and 164.
As shown in Figures 6 and 7, the shaft 159 is rotatably driven by the feed motor35 through a suitable drive train which may include a chain 165 trained around a sprocket
CA 02223413 1997-12-03
WO ~'1û 136 PCT~US~ fJgS12
on the shaft 159 and a driven sprocket, with a resiiientiy biased take-up being provided
to accommodate movement of the shaft 159. Also, the sprocket 150 may be mounted
to the shaft 159 as an expedient means for effecting synchronous rotation of therotating members of the outer feed and connecting assemblies 108 and 109. As is
further evident from Figure 7, the outer feed assembly 100 and the connecting
assembly 109 engage the outer layer at transversely aligned locations relative to a
movement path of the first layer.
Although details of the method of forming a dunnage product according to the
invention have been mentioned above in connection with the desc,i~,Lion of the
10 structure of the machine, by way of summary a method accord;"g to the invention
comprises the steps of shaping an outer layer of the stock material into a tube with the
lateral edge portions being brought into overlapping relationship, connecting the
overlapped lateral edge portions of the outer layer to form a tubular casing, shaping an
inner layer or layers of the stock material into a stuffing for the for the casing, and
15 feeding the stuffing into the interior of the casing. The overlapped lateral edge portions
are generally coplanar with adjacent unoverlapped portions of said outer layer during the
connecting step. Pl~:ft(ably, the layers of stock material co-.,prise biodegradable,
recyclable and reus~hle Kraft paper. Also, as is apparent from the foregoing
clesc,i~,lion, the step of connecting the overlapped lateral edge portions includes using a
20 pair of rotating connecting members forming therebetween a nip through which the
overlapped lateral edge portions of the outer layer pass. Moreover, the feeding step
uses the pair of rotating crumpling members forming therebetween a nip though which
the inner layer or layers pass and are crumpled thereby.
The cutting assembly 38 is used to cut the thus produced continuous strip at a
25 desired length to form a cushioning product. In this manner, the length of the
cushioning product may be varied depending on the intended application. The particular
construction and operation of the strip-cutting assembly is not essential to the present
invention. However, reference may be had to U.S. Patent Application No. 08/110,349
for a cutting assembly similar to that illustrated.
Referring now to Figure 8, a cushioning product according to the invention is
schematically illustrated at 175. The cushioning product 175 comprises at least and
preferably two, three or more inner layers 57 and 58 of sheet-like material having
portions thereof folded upon themselves and crumpled to produce a stuffing 176
loosely connected along central band 177, and an outer layer 56 of sheet-like material
35 formed into a tubular casing 179 surrounding the stuffing and having lateral edge
CA 022234l3 l997-l2-03
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16
portions overlapped and stitched together along a central band 180 separate from the
stuffing 176. The overlapped lateral edge portions are generally coplanar with adjacent
unoverlapped portions of the first layer, and the layers of stock material comprise
biodegradable, recyclable and reusable Kraft paper, as above mentioned. ?
Referring now to Figures 9 and 10, an exemplary embodiment of a cushioning
conversion machine according to the invention is designated generally by reference
numeral 1030. The machine includes a housing 1031 which forms the structural
skeleton for the conversion assemblies of the machine 1030. The conversion
assemblies include a stock supply assembly 1032, a forming assembly 1033, a
feed/connecting assembly 1036 powered by a feed motor 1037, and a cutting
assembly 1038. These assemblies of the machine 1030 cooperate to convert sheet-like
stock material into a cushioning product according to the present invention. The roles
the conversion assemblies and components thereof play in the creation of such a
cushioning product are explained below in detail. In regard to the various functions
performed by the noted assemblies and components thereof, the terms (including areference to a "means") used to identify the herein-described assemblies and devices
are intended to cor.espond, unless otherwise indicated, to any assembly/device which
performs the specified function of such an assembly/device, that is functionallyequivalent even though not structurally equivalent to the disclosed structure which
performs the function in the illustrated exemplary embodiment of the invention.
The illustrated machine 1030, representing a preferred embodiment of the
invention, is designed to convert multi-layer stock material into a cushioning product.
Preferably, the stock material comprises at least two and preferably three or more
superimposed layers which may be supplied in the form of a stock roll. These layers
are each preferably 27-30 inches wide, and comprised of biodegradable, recyclable and
reusable 30-50 pound Kraft paper.
The housing 1031 includes a frame 1042 to which the conversion assemblies of
the machine are mounted. The frame includes upright legs and various cross framemembers similar to the frame found in the well known PADPAK machines provided byRanpak Corp. of Concord, Ohio. However, it will be appreciated that the invention may
be applied to other types of machines. The housing preferably has an outer sheet metal
skin enclosing the interior conversion assemblies of the machine. The top wall of the
housing may include an openable cover for permitting easy access to the components
of the machine located inside the housing.
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The illustrated stock supply assembly 1032, located at the rear or upstream end
(to the left in Figures 9 and 10) of the machine 1030, includes a holder assembly 1054
for a stock roll 1055. The illustrated stock roll consists of three superimposed plies or
layers 1056-10580f biodegradable, recyclable and reusa~lE thirty-pound Kraft paper
5 rolled onto a hollow cylindrical tube. The stock roll may be supported by a spindle
1060 or other stock roll holder device, such as that shown in U.S. Patent Application
No. 08/267,960, between the lower arms of a pair of brackets 1061 provided, as
shown, with slots 1062 for receiving the ends of the spindle. The stock roll holder
assembly 1054 need not be mounted to the machine housing as shown, but instead
10 may be separate from the machine housing as in the form of a cart, especially when
large and thus heavy stock rolls are used.
The brackets 1061, which are secured to the rear of the housing 1031, have
upper arms 1064 extending horizontally away from the housing and terminating at
depending arms 1065. The upper and depending arms have journalled therebetween
15 guide rollers 1067 and 1068 over which the superimposed layers of stock material are
trained. Between the guide rollers, the superimposed layers of stock material are
passed over a splicing plate 1070 ex~end ,g transversely between the depending arms
1065. The depending arms also have paper clamps 1072 mounted thereto on opposiLesides of the path of the stock material. The paper clamps are spring biased against an
20 adjacent cldll,pin~ surface and are roldlable from a position clear of the stock material
path to a position overlaying the stock material path, such that when released the
clamps are operative to hold the stock material to the clamping surface downstream of
the splicing plate 1070. It is noted that the terms "upstream" and "downstream" are
herein used in relation to the direction of flow of the stock material through the machine
25 1030. When the trailing ends of the layers of a spent stock roll are thus held, the
leading ends of the layers of a next stock roll may be spliced to the trailing ends. The
splicing plate provides a surface along which the layer ends may be cut to provide
straight edges for splicing.
From the guide roller 1068, the layers of stock material pass to separators 1075-
30 1077 which separate the plies from one another. The separators preferably are rollersjournalled between the upper arms 1064 of the brackets 1061. From the separators,
the layers of the stock material pass to the entry end of the forming assembly 1033.
The forming assembly 1033 includes a shaping chute 1082 and a former 1083 which
cooperate to turn inwardly the edges of the layers to form a tubular strip of cushioning.
35 The illustrated shaping chute (a converging chute as the cross section of the chute
CA 022234l3 l997-l2-03
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progressiveiy decreases) and former generally are of the type shown in U.S. Patent Nos.
4,717,613 and 4,750,896.
As best shown in Figures 14-16, the converging chute 1082 has side walls
1084 which turn towards one another to roll lateral edge portions of the inner layers
5 toward one another. In addition to this rolling action, the inner layers will crumple
because of the progressively decreasing cross-section of the converging chute. The '
chute is modified from previously used chutes by providing a more downwardly sloped
bottom wall 1085 to allow the central portions of the layers to exit the downstream end
of the chute at a lower elevation spaced further from the overlapped lateral edge
10 portions of the strip. As best shown in Figures 11-13, the former 1083 is in the
form of a triangular frame having open U-shape guide surfaces 1088 and 1089 of
progressively decreasing height and width going from the upstream to the downstream
end of the former.
As shown in Figures 9 and 10, the former extends into the converging chute
15 through the wider end thereof with the nose 1090 of the former positioned at about the
downstream end of the converging chute. The former is mounted in known manner tothe frame by adjustable posts 1092 and further is provided with various stiffening
members 1093 as needed to rigidly support the former and portions thereof.
The converging chute 1082 and former 1083 cooperate in well known manner
20 to roll the layers of stock paper inwardly and bring the lateral edge portions thereof into
overlapping relationship to form an unconnected strip of cushioning for passage to the
feed/connecting assembly 1036. In the illustrated embodiment of the invention, the
feed/connecting assembly functions to connect together the overlapped lateral edge
portions of the layers as well as to feed the stock material through the machine. The
25 feed/connecting assembly includes a pair of gear-like members 1100 and 1102, often
simply referred to a gears, forming therebetween a nip through which pass the
overlapped lateral edge portions of the layers of stock material. The rotating connecting
members may be toothed gear-like members of the type described in commonly
assigned U.S. Patent No. 4,968,291, or any other pair of roldLi,lg devices that provide
30 for secure stitching together of the outer layer edge portions, such as the hereinafter
described preferred embodiment of stitching gears.
The upper gear 1100 is rotatably mounted to the frame 1042 and rotaldbly
driven by the feed motor 1037 through a chain drive mechanism 1103. The lower gear
1102 is mounted in a clevis 1105 formed at the downstream end of a mounting bracket
1106 attached to the nose end of the former 1083 as best shown in Figures 11 -13.
CA 02223413 1997-12-03
WO ~/101~6 PCT~US9C~6~2
19
The mounting bracket is sufficiently narrow such that the side portions of the layers
may be folded therearound into a tubular shape and the laterally outer edge portions
brought into an interleaved overlapping relationship prior to passage of such overlapped
edge portions between the gears. As the overlapped edge portions are pulled between
5 the gears, they are stitched together by the gears and thereby connected to resist
opening or unzippering of the strip which may be detrimental to its cushioning and/or
handling properties.
Unlike the conversion machines shown in the aforesaid U.S. Patents wherein
both the edge portions and center portions of the layers are all passed between the
10 gears, in accordance with the present invention only the overlapping edge portions of
the layers are passed between the rotating gears while the center portions of the layers
are guided along a path outside of the IO~aLin9 gears. To this end, a guide finger plate
1 1 10 is mounted to the bracket 1 106 to push the center portions of the layersdownwardly and clear of the loLaLing gears 1 100 and 1 102 for passage along a bottom
15 guide plate 1112 which supports the center portion of the layers. The guide figure
plate extends to a point partially underlying the gear 1102 sufficiently to prevent the
center portions of the layers from being drawn into the nip of the gears. A top guide
1 1 14 may also be provided as shown.
As a result of the foregoing, all of the overlapped edge portions are stitched
20 together independently ~separately) of the center portions of the layers. This adds to
the loft or reduced density of the finished cushioning or dunnage product. If desired,
the center portions of the layers may be advanced by a second pair of rot~ .g gears, as
in a manner similar to that described herein.
The cutting assembly 1038 is used to cut the thusly produced continuous strip
25 at a desired length to form a cushioning product. In this manner, the length of the
cushioning product may be varied depending on the intended application. The particular
construction and operation of the strip-cutting assembly is not essential to the present
invention. However, reference may be had to U.S. Patent Application No. 08t386,355
for a cutting assembly similar to that illustrated, or to U.S. Patent Application No.
30 08/1 1 0,349for another type of cutting assembly.
Referring now to Figures 17 and 18, details of the gears 1 100 and 1 102 can be
seen. Although particularly useful in the above described machine, the gears may be
used in place of the presently known gears (gear-like members in other conversion
machines). It is noted that the new gear-like members may be used to perform both the
35 stitching and feed functions previously performed by presently known gear-like
CA 022234l3 l997-l2-03
W O 96'10'~6 PCT~US96~'~5C~12
members, or just the stitching function while other means are provided to perform the
feed function, such as one or more feed assemblies for pushing and/or pulling the stock
material through the machine and/or sub-components thereof.
The gear 1102, herein also called the female stitching gear or wheel, has around5 the circu,-,ference thereof a plurality of radially outwardly extending projections 1120
preferably in the form of teeth, such as the illustrated spur gear teeth. The teeth 1120
are divided into a central segment 1122 and outer or side segments 1124 by annular
recesses or grooves 1126. The segments and grooves prererably are symmetrically
disposed with respect to the center plane 1128 of the female gear.
The other gear 1100, herein also referred to as the male stitching gear or wheel,
includes a central segment 1130 and axially adjacent side segments 1132 herein
referred to as punch or perfordli"g segments. The central segment 1130 has around
the circu",ferel-ce thereof a plurality of radially outwardly extending projections 1134,
preferably teeth such as the illu:iL~dLed spur gear teeth, meshing with the teeth 1120 of
16 the central segment 1122 of the female stitching gear 1102. The punch segments
1132 each have around the circ--,-,ference thereof a plurality of radially outwardly
extending projections 1138 having a width slightly less than the width of the respective
grooves 1126 in the female gear and thus dimensioned to be received in the annular
grooves during rotation of the stitching gears. The projections 1138 on the punch
20 segments 1132 have the same pitch as the teeth 1134 of the central segment 1130,
but are offset circumferentially by one half pitch, whereby they are aligned with the
spaces or valleys 1142 between the teeth 1134 of the central segment 1130 that
receive the teeth 1120 of the female gear during rotation of the gears. Consequently,
during rotation of the gears, the projections 1138 (or punches) will move past the
25 synchronously moving teeth of the female stitching gear.
For easy fabrication of the male gear 1100, the punch segments 1132 may be
formed on disc inserts 1141 attached to a main gear body 1143 including the central
segment 1130, as shown. The punch segments have axially extended hubs 1146 fitted
over axial hub projections at respective sides of the main gear body, with threaded
30 holes 1148 being provided for receiving set screws which lock the inserts against
rotation relative to the main gear portion. As also shown, the male gear is keyed to the
driven shaft 1150 and the female gear may have a bushing 1152 in a centerbore
thereof for rotating on its shaft. The hubs 1146 have an outer diameter equal the
diameter of the base circle of the teeth 1134.
CA 022234l3 l997-l2-03
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21
The edges of the punch segment projections 1138 (or at least the leading edges)
preferably form with the sides thereof sharp corners which function as cutting or knife
edges. Similarly, the edges (at least the leading edyes) of the teeth 1120 of the female
ç~ear 1102 adjacent the annular grooves 1126 form sharp cor"ers with the side walls of
the grooves, also to function as a cutting or knife edges in cooperative relationship with
the cutting edges of the punch segment projections.
As should now be evident, the gears 1100 and 1102 will rotate synchronously
because of the meshed central se~ments of the gears which are about equal in width.
The meshing gears pull the overlapped lateral edge portions of the stock material
10 therebetween and while doing so will form dents or indentations in the stock material
and thus thereby coin the stock material. At the same time, the punch segment
projections will move past the teeth of the female ~ear. At the nip of the gear, the then
juxtaposed punch segment projection 1138 and female gear tooth 1120 will cause the
portions of the stock material radially outwardly thereof to move in opposite directions
15 while the cutting edges coope,ale to create a shearing action forming a slit through
each one of the overlapped layers at each side of a thus formed tab portion being
punched by the punch segment projection. To prevent tearing of the stock material
other than at the slits, the several projections may be rounded at their radially outer
ends.
Referring now to Figures 19 and 20, a cushioning product according to the
invention is schematically illustrated at 1175. The cushioning product comprises at
least two and preferably three, or more, layers 1177-1179 of sheet-like material having
lateral edge portions thereof folded over the center portions and interleaved as seen at
1182. The overlapped and interleaved lateral edge portions 1182 are stitched together
along a central seam or band 1183 separate from the central portions 1185 of thelayers which are crumpled and provide loft to the cushioning product. The overlapped
lateral edge portions 1182 are generally coplanar with adjacent unoverlapped portions
of the first layer, and the layers of stock material comprise biodegradable, recyclable
and reusable Kraft paper, as above mentioned.
As shown, the stitching pattern produced by the stitching gears includes a
central row 1187 of outwardly directed dents 1188 alternating with a inwardly directed
dents 1189. The central row of dents is bounded at each side thereof by a row 1190 of
tabs 1191. The tabs, which are defined by laterally spaced apart slits 1193, are dented
or punched from the layer of stock material in a direction opposite the relatively
adjacent dent of the central row.
,
CA 022234l3 l997-l2-03
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Although details of the method of forming the dunnage product according to the
invention have been mentioned above in connection with the desc,i,~.lion of the
structure of the machine, by way of summary a method according to the invention
comprises the steps of shaping plural layers of the stock material into a tube with the
5 lateral edge portions being brought into overlapping relationship and connecting the
overlapped lateral edge portions of the outer layer separately from central portions of
the layers. The overlapped lateral edge portions are generally coplanar with adjacent
unoverlapped portions of the outer layer during the connecting step. Preferably, the
layers of stock material comprise biodegradable, recyclable and reusable Kraft paper.
10 Also, as is apparent from the foregoing desc~ lion, the step of connecting the
overlapped lateral edge portions includes using a pair of ~olc,lil,g connecting members
forming therebetween a nip through which the overlapped lateral edge portions of the
outer layer pass.
Although the invention has been shown and desc,iLed with respect to certain
15 prere"ed embodiments, it is obvious that equivalent alterations and modifications will
occur to others skilled in the art upon the reading and under~iLa~lding of this
specification. The present invention includes all such equivalent alteralions and
modifications.
