Off-set gears and methods of using off-set gears for producing cushioning material

Abstract

Some embodiments of the present invention comprise an off-set gear assembly for use in producing cushioning material and methods for using the same. Each gear of the off-set gear assembly has at least two sections. Each section includes a set of gear teeth. The gear teeth of the two sections can be rotationally off-set and this can result in the production of cushioning material with staggered ridges. Some embodiments of the present invention also comprising cushioning material with staggered ridges.

What is claimed is: 
     
         1 . A gear assembly for use in producing cushioning material comprising:
 at least a first rotatable gear and at least a second rotatable gear, each rotatable gear having at least a first set of gear members and at least a second set of gear members, each of the sets of gear members having a plurality of gear members arranged in circumferential fashion about a perimeter of the corresponding rotatable gear, with each gear member of the at least first set of gear members being rotationally off-set from each gear member of the at least second set of gear members.   
     
     
         2 . The gear assembly of  claim 1  wherein there is a gap between the at least first set of gear members and the at least second set of gear members on each rotatable gear. 
     
     
         3 . The gear assembly of  claim 2  wherein the gap is between approximately ¼ inch and ½ inch in width. 
     
     
         4 . The gear assembly of  claim 2  wherein a ratio of the width of the gap divided by a lateral width of at least one of the gear members is between approximately 0.3 and 0.5. 
     
     
         5 . The gear assembly of  claim 1  wherein the rotational off-set between the gear members is between approximately 4 degrees and approximately 12 degrees. 
     
     
         6 . The gear assembly of  claim 1  wherein the first rotatable gear is a driving gear having a notch in a first aperture of the first rotatable gear, the notch being capable of being coupled to a protrusion on a drive shaft to drive the driving gear and the second rotatable gear is a driven gear having an second aperture configured to allow the second rotatable gear to freely rotate about a shaft passing through the second aperture. 
     
     
         7 . A method of producing dunnage comprising:
 providing at least a first gear having a plurality of gear members disposed about a perimeter of the first gear in spaced apart fashion and a plurality of adjacent gear members also disposed about the perimeter of the first gear in spaced apart fashion, each of the adjacent gear members of the first gear being in disposed in an off-set position relative to each of the gear members of the first gear;   providing at least a second gear having a plurality of gear members disposed about a perimeter of the second gear in spaced apart fashion and a plurality of adjacent gear members also disposed about the perimeter of the second gear in spaced apart fashion, each of the adjacent gear members of the second gear being disposed in off-set position relative to the each of the gear members of the second gear;   moving the first gear and the second gear in a manner such that at least some of the gear members and adjacent gear members associated with the first gear overlap with at least some of the gear members and adjacent gear members associated with the second gear; and   compressing a stock material between the gear members and adjacent gear members of the first gear and gear members and adjacent gear members of the second gear to form a cushioning material.   
     
     
         8 . The method of  claim 7  wherein prior to compressing the stock material, the stock material is laterally roll to form overlapping edge portions of stock material, with the overlapping edge portions being laterally centrally positioned on the stock material. 
     
     
         9 . The method of  claim 8  wherein the overlapping edge portions of the stock material are passed between the first gear and second gear. 
     
     
         10 . The method of  claim 9  wherein the overlapping edge portions are formed to have a plurality of ridges. 
     
     
         11 . The method of  claim 10  wherein the ridges comprise at least two sets of ridges that are staggered in relation to one another. 
     
     
         12 . The method of  claim 10  wherein the ridges comprise at least three sets of ridges with at least one set of ridges being diagonally configured with respect to other sets of ridges. 
     
     
         13 . The method of  claim 7  wherein each of the gears is circular in shape and wherein the gear members and adjacent gear members are disposed circumferentially about the perimeters of the gears, and wherein the adjacent gear members are rotationally offset from the gear members. 
     
     
         14 . The method of  claim 13  wherein the adjacent gear members are rotationally offset from the gear members by about 4 degrees to about 12 degrees. 
     
     
         15 . The method of  claim 13  wherein there is a gap between each gear member and each adjacent gear member. 
     
     
         16 . The method of  claim 15  wherein a ratio of the width of the gap divided by a width of at least one of the gears is between about 0.3 and about 0.5. 
     
     
         17 . A cushioning product comprising:
 a stock material having overlapping edge portions, the overlapping edge portions having at least a first set of ridges and at least a second set of ridges, each of the sets of ridges including a plurality of longitudinally spaced apart ridges, with the at least first set of ridges also being laterally space apart from the at least second set of ridges.   
     
     
         18 . The cushioning product of  claim 17  further comprising at least a third set of ridges wherein at least one ridge of the third set of ridges is connected at least one of the ridges in the first set of ridges and to at least one of the ridges in the second set of ridges. 
     
     
         19 . The cushioning product of  claim 17  further comprising pillow-like portions positioned laterally outward of the overlapping edge portions, the pillow-like portions extending longitudinally along a length of the cushioning product. 
     
     
         20 . The cushioning product of  claim 17  further comprising at least a third set of ridges that are diagonally configured in relation to the first and second set of ridges.