Method and apparatus for producing a resilient product

What is claimed is:

1. A method of producing a product from a sheet of material having a natural resilience, said method comprising the steps of:

slitting the sheet of material into a plurality of strips to form a body of such strips, said slitting being performed by a slitting device; and

sequentially folding each of the strips into a zig-zag shape, wherein said sequentially folding step is accomplished by advancing the plurality of strips against a restriction acting on the body of strips in such a manner that the natural resilience of the material produces substantially uniform adjacent opposite folds thereby causing each of the strips to assume substantially the same zig-zag shape.

2. The method of claim 1, wherein the restriction comprises at least one pair of longitudinally extending walls, positioned downstream of the slitting device.

3. The method of claim 2, which further comprises adjusting the degree of restriction provided by the walls.

4. The method of claim 3, wherein the walls are angularly adjusted in relation to a discharge chute positioned downstream of the slitting device.

5. The method of claim 1, wherein the restriction comprises a downstream moveable barrier.

6. The method of claim 5, which further comprises moving the barrier automatically away from the slitting device to provide a controlled metered release of the plurality of zig-zag folded strips.

7. The method of claim 1, wherein the sheet of material is biodegradable.

8. The method of claim 1, which further comprises transversely cutting the sheets into segments and separating the segments upstream of the restriction.

9. The method of claim 1, wherein the slitting device comprises at least two sets of cutting discs.

10. The method of claim 9, wherein the slitting discs have smooth cylindrical outer surfaces, and the advancing of the strips is accomplished by rotation of said outer surfaces.

11. The method of claim 9, wherein the slitting discs include opposed side surfaces and the step of advancing is further accomplished by rotation of the side surfaces.

12. The method of claim 1, which further comprises cutting the plurality of zig-zag folded strips transverse to the slitting.

13. The method of claim 1, wherein the sheet of material comprises multiple layers of material.

14. The method of claim 13, which further comprises the step of transversely cutting the sheet of material into segments with sufficient force such that the ends of the multiple layers of material become bonded.

15. The method of claim 14, wherein the multiple layers of material form substantially aligned folds.

16. The method of claim 1, which further comprises the step of mixing the plurality of strips to form a mass of intertwined strips.

17. The method of claim 1 where the sheet of material comprises a pulp-based material.

18. The method of claim 17 where the pulp-based material is selected from a group consisting of Kraft paper and cardboard.

19. The method of claim 1 further comprising cutting the strips.

20. The method of claim 19 wherein said cutting of the strips is performed after the folding step.

21. An apparatus for producing a resilient product from a sheet of material having a natural resilience, said apparatus comprising:

means for slitting the sheet of material into a plurality of strips, whereby to form a body of such strips, said means for slitting including a slitting device, and,

means for advancing the plurality of strips against a restriction acting on the body of strips in such a manner that the natural resilience of the material produces substantially uniform adjacent opposite folds thereby causing each of the strips to assume substantially the same zig-zag shape.

22. The apparatus of claim 21, wherein the restriction comprises at least one pair of longitudinally extending walls, positioned downstream of the slitting device.

23. The apparatus of claim 22, which further comprises means for adjusting the degree of restriction provided by the walls.

24. The apparatus of claim 23, wherein said walls can be angularly adjusted in relation to a discharge chute positioned downstream of the slitting device.

25. The apparatus of claim 21, wherein the restriction comprises a downstream moveable barrier.

26. The apparatus of claim 25, which further comprises means for moving the barrier away from the slitting device to provide a controlled release of the plurality of folded zig-zag strips.

27. The apparatus of claim 21, wherein the sheet of material is biodegradable.

28. The apparatus of claim 21, which further comprises means for transversely cutting the sheet into segments and separating the segments upstream of the restriction.

29. The apparatus of claim 21, wherein the slitting device comprises at least two sets of slitting discs.

30. The apparatus of claim 29, wherein the slitting discs have smooth cylindrical outer surfaces, and the advancing of the strips is accomplished by rotation of said outer surfaces.

31. The apparatus of claim 29, wherein the slitting discs have opposed side surfaces and the step of advancing is further accomplished by rotation of the side surfaces.

32. The apparatus of claim 21, which further comprises the means for cutting the plurality of zig-zag folded strips transverse to the slitting.

33. The apparatus of claim 21, wherein the sheet of material comprises multiple layers of material.

34. The apparatus of claim 33, which further comprises means for transversely cutting the sheet of material into segments with sufficient force such that the ends of the multiple layers of material become bonded.

35. The apparatus of claim 34, wherein the multiple layers of material form substantially aligned folds.

36. The apparatus of claim 21, which further comprises means for mixing the plurality of strips to form a mass of intertwined strips.

37. The apparatus of claim 21 where the sheet material comprises a pulp-based material.

38. The apparatus of claim 37 where the pulp-based material is selected from a group consisting of Kraft paper and cardboard.

39. The apparatus of claim 21 further comprising a cutter which cuts the strips.

40. The apparatus of claim 39 wherein said cutter is positioned upstream of the means for advancing.

41. A method of producing a paper product from a sheet of paper, said method comprising the steps of:

cutting the sheet of paper into a plurality of strips, whereby to form a body of such strips, said cutting being performed by a cutting device; and

sequentially folding each of the strips into a zig-zag shape, characterized in that said sequentially folding step is accomplished by advancing the plurality of strips against a restriction acting on the body of strips in such a manner that the natural resilience of the paper produces substantially uniform adjacent opposite folds thereby causing each of the strips to assume substantially the same zig-zag shape.

42. The method of claim 41, wherein the restriction comprises at least one pair of longitudinally extending walls, positioned downstream of the cutting device, and which further comprises adjusting the degree of restriction provided by the walls.

43. The method of claim 42, wherein the walls are angularly adjusted in relation to a discharge chute positioned downstream of the cutting device.

44. The method of claim 41, which further comprises transversely slitting the sheets into segments and separating the segments upstream of the restriction.

45. The method of claim 41, which further comprises slitting the plurality of zig-zag folded strips transverse to the cutting.

46. The method of claim 41, wherein the sheet of paper comprises multiple layers of paper.

47. The method of claim 46, which further comprises the step of transversely cutting the sheet of paper into segments with sufficient force such that the ends of the multiple layers of paper become bonded.

48. The method of claim 47, wherein the multiple layers of paper form substantially aligned folds.

49. An apparatus for producing a paper product from a sheet of paper, said apparatus comprising:

means for cutting the sheet of paper into a plurality of strips, whereby to form a body of such strips, said means for cutting including a cutting device,

characterized by the inclusion of means for advancing the plurality of strips against a restriction acting on the body of strips in such a manner that the natural resilience of the paper produces substantially uniform adjacent opposite folds thereby causing each of the strips to assume substantially the same zig-zag shape.

50. The apparatus of claim 49, wherein the restriction comprises at least one pair of longitudinally extending walls, positioned downstream of the cutting device and which further comprises means for adjusting the degree of restriction provided by the walls.

51. The apparatus of claim 50, wherein said walls can be angularly adjusted in relation to a discharge chute positioned downstream of the cutting device.

52. The apparatus of claim 49, which further comprises means for transversely slitting into segments and separating the segments upstream of the restriction.

53. The apparatus of claim 49, which further comprises the means for slitting the plurality of zig-zag folded strips transverse to the cutting.

54. The apparatus of claim 49, wherein the sheet of paper comprises multiple layers of paper and which further comprises means for transversely cutting the sheet of paper into segments with sufficient force such that the ends of the multiple layers of paper become bonded.

55. A method for producing a product from a sheet of paper, said method comprising the steps of simultaneously slitting the sheet of paper into a plurality of strips to form a body of strips and sequentially folding each of the strips into a zig-zag shape;

wherein said sequentially folding step is accomplished by advancing the body of strips against a restriction acting on the body of strips;

wherein said advancing step includes advancing the strips through a common discharge chute and towards an exit opening in the discharge chute.

56. An apparatus for producing a product from a sheet of paper, said apparatus comprising means for simultaneously slitting the sheet of paper into a plurality of strips to form a body of strips and means for sequentially folding the plurality of strips;

wherein said sequentially folding means includes means for advancing the plurality of strips against a restriction acting on the body of strips; and

wherein said means for advancing includes a common discharge chute having an exit opening towards which the strips are advanced.

57. A method of producing a product from a sheet of material having a natural resilience, said method comprising the steps of:

slitting the sheet of material into a plurality of strips to form a body of such strips, and

sequentially folding each of the strips into a zig-zag shape wherein said sequentially folding step is accomplished by advancing the plurality of strips against a restriction acting on the body of strips in such a manner that the natural resilience of the material produces adjacent opposite folds thereby causing each of the strips to assume a zig-zag shape.

Description Submit all comments and votes

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a resilient packing material or the like and to the method and apparatus for making the same. More particularly, this invention relates to apparatus and methods for resiliently folding and crimping shredded strips of sheet material into selected lengths of interlocking, bulk, packaging material.

2. Description of the Prior Art

Styrofoam pellets or peanuts are commonly used within the wholesale and retail industries as bulk packaging material. The peanuts are used to position a product away from the interior sides of a container and fill the empty space located therebetween. The peanuts are intended to protect the packaged product against the impact of a blow or other mistreatment.

Dispensing styrofoam peanuts does not require a great degree of sophistication. The peanuts are simply gravity fed from large retainer bins into the empty spaces within a packaging container.

Use of styrofoam peanuts, however, has many drawbacks. For example, if styrofoam peanuts are used to protect a heavy object placed within a container, and such package is jostled and shaken, the object usually gravitates toward the bottom of the container and the peanuts float upward. Eventually the object comes to rest against the base or side of the container and damage to the object may occur. The light weight of the styrofoam peanuts also allows them to be easily blown by the wind and scattered.

Of particular concern, styrofoam peanuts are extremely difficult to dispose of and destroy after use. In fact, because of the extensive use of this nonbiodegradable product, which emits toxic gases if burned, styrofoam peanuts present a major threat to the environment and are being banned from an increasing number of communities.

Styrofoam peanuts are also dangerous to children and to wildlife who often mistake them as food and consequently ingest them. Styrofoam peanuts are not digestible and cause a major source of tracheal blockage in children.

Other packaging filler materials, such a shredded paper, have also been used. Shredded paper, however, usually lays flat within the container and a very large amount of paper is required to provide the bulk needed to fill the voids and to protect the contained object. To provide such a large amount of shredded paper is often cost prohibitive and, following its use, such voluminous amounts of paper must be disposed. In addition, the shock absorbency of flat shredded paper is minimal.

A number of patents are directed to the folding or crumpling of large sheets of materials. Specifically, U.S. Pat. Nos. 2,668,573; 3,150,576; and 4,012,932 are directed to the corrugation or pleating of large sheets of paper material.

Complicated sheet creping, crinkling or folding is disclosed in U.S. Pat. Nos. 1,680,203 and 3,501,565. However, U.S. Pat. No. 3,501,565 simply includes preliminary steps prior to the stretching of plastic sheet material or the like.

Other patents discuss the crumpling of sheet paper material or the like for the formation of filters. U.S. Pat. No. 2,786,399 includes such crumpled sheet paper material and employs a cutter for the formation of small blocks of such material. U.S. Pat. No. 2,924,154 is directed to filter material and employs a gate means during the advancement of the sheet material to assist in the formation of the crumpled blocks of material.

Various methods and apparatus for forming dunnage are disclosed in several patents which include the folding or funneling of sheet paper or material into a compact elongated form. U.S. Pat. Nos. 3,509,797; 3,613,522; and 3,650,877 include such elongated dunnage material which is twisted and compressed to provide a helical shape. U.S. Pat. Nos. 4,085,662; 4,650,456; and 4,699,609 disclose additional devices for the folding and collapsing of elongated sheet material. Some of these patents directed to dunnage include cutter means at the outlets in order to provide predetermined lengths of the dunnage material.

U.S. Pat. Nos. 3,754,498 and 4,201,128 generally disclose shredding machines which are used in conjunction with compacters or bailers.

U.K. Patent No. 771,877 and U.S. Pat. No. 3,217,988 disclose cutting discs for producing a longitudinal cut of sheet material to form longitudinal strips. Outlet support means is provided for supporting the longitudinal strips during a transverse cut to form smaller pieces.

U.S. Pat. Nos. 2,621,567; 2,686,466; and 2,770,302 disclose shredding devices which include a comber configuration for imparting a bend or kink to the strips which are cut thereby.

It is felt that the known prior art taken alone or in combination neither anticipate nor render obvious the present invention. These citations do not constitute an admission that such disclosures are relevant or material to the present claims. Rather, these citations relate only to the general field of the disclosure and are cited as constituting possible prior art for consideration.

OBJECTS OF THE INVENTION

It is the general object of the present invention to provide apparatus and methods for rapidly folding large quantities of shredded strips or strands of sheet material into continuous or segmented lengths of folded and crimped, interlocking, bulk packaging material, such apparatus being: sturdy and durable in design; compact; easily constructed; inexpensive to manufacture; and economical and simple to operate.

A further object is to provide one embodiment of the invention including apparatus and methods for producing large quantities of folded and crimped, shredded strips of sheet material which: avoid interference with the otherwise normal operation of conventional shredding device; does not require permanent modification of the shredding device's structure, or defacement or mutilation thereof; and may be used on any commercial shredding device, irrespective of its design or general configuration.

A still further object is to provide apparatus and methods for a commercial shredding device which allows for quick and easy adjustment of the device to selectively extend or shorten the length of the shredded, folded, and crimped strips of sheet material into segment lengths which would otherwise be commercially impossible, and to do so without requiring modification of the devices's mechanics, or any careful or critical attention by the operator.

Another object is to produce a series of folded interlocking strips of bulk packaging material which are produced from colored sheet material and may be made from a large variety of different colors or controlled combinations of colors.

Another object is to produce the folded, interlocking strips from biodegradable pulp materials such as from paper, cardboard, and the like, the composition of which may be edible and is approved by the U.S. Federal Food and Drug Administration (FDA) for use in packaging edible products.

It is also an object of the present invention to provide another preferred machine which is particularly adapted for and capable of producing the desired packing product.

It is also an object to provide such a machine which feeds sheet material to a cutting section for the sequential folding of longitudinal strip means formed in the cutting section.

It is a further object of the invention to produce the strip means of material having a natural resilience so that the sequential folding causes the strip means to be longitudinally compressed and capable of resilient expansion during use.

It is yet another object of the invention to provide an overall packing product comprising a plurality of intertwined and intermixed strip means which have been longitudinally compressed in order to provide overall resilience and resistance to compression of the packing product.

SUMMARY OF THE INVENTION

The present invention achieves these general and specific objects and presents new apparatus and methods for producing a bulk packaging material which incorporates therein the beneficial features of both styrofoam peanuts and shredded paper. The present invention also overcomes each of the previously mentioned disadvantages.

In short, this invention provides apparatus and methods for rapidly producing large quantities of bulk packaging material comprising folded and crimped, interlocking strips of sheet material which may:

(a) be used as a resilient padding to cushion and prevent heavier objects from gravitating toward the bottom and/or sides of a container, such padding requiring a lesser amount of raw material to form a greater amount of interlocking bulk packaging material than was previously available;

(b) be produced with selectable lengths, smaller lengths capable of being gravity fed into a container to fill the void left by the banning of styrofoam peanuts, larger lengths capable of being wrapped around a product to provide a secure protective cushion;

(c) be produced in selectable colors and/or controlled color combinations for decorative and aesthetic purposes;

(d) be manufactured from biodegradable material, such as pulp material (i.e., paper, cardboard, or the like); and

(e) be edible and/or approved by the U.S. Federal Food and Drug Administration (FDA) for use in packaging edible products.

One embodiment of the invention can comprise an attachment for a commercial shredding machine or device. Such an attachment can be a simple, compact, rugged, inexpensive, movable barrier which is easily attached and employed. In this embodiment, the present invention does not necessarily require the defacement or alteration of the shredding device's structure. In essence, the attachment modifies the shredding device to cause a sheet material, such a mylar, paper, cardboard, or the like, which is fed therethrough, to be impacted or impelled against a barrier after having passed through a series of cutting blades in the shredding device.

The barrier causes the shredded sheet material to become controllably jammed between the barrier and the cutting blades. The continued rotation of the cutting blades forces additional amounts of sheet material into the shredding machine and cutting blades. As a result, each shredded strip of sheet material is folded against itself in a relatively controlled manner, thereby, repetitively folding and crimping or creasing each strip and compacting it within a confined space or area against a remaining dam of jammed shredded strips. The resulting effect is the folding or crimping of each cut strip into an accordion-shaped mass.

The confined area referably is located near an exit opening of the shredding device through which the shredded strips pass.

As pressure builds up behind the confined mass of shredded strips, a pressure sensitive gate, in one embodiment, opens to allow the escape of a portion of the jammed strips. The gate controllably maintains the confinement of a remaining portion of jammed strips within the confined area. The gate thus allows the continuation of additional lengths of shredded sheet material to be folded and pressed against the remaining dam of jammed strips without the modified device actually becoming jammed to the point of requiring servicing.

This means for controllably jamming the paper within the confined area may comprise a simple, movable barrier which is placed near the exit opening of the shredding device. The barrier causes the shredded strips of sheet material to temporarily remain within a confined area located between the barrier and the cutting blades of the shredding device.

The confined area may be of a fairly small or large volume, the boundaries of which are initially defined by the barrier, the cutting blades, and possibly a lower, upper, and side support elements. After a partial dam of shredded strips has been achieved, the dam itself further limits the volume of space remaining within the confined area. As long as a partial dam of shredded strips remains within the confined area, such shredded strips serve the purpose of the movable barrier, and may even eliminate the need for continued use of the gate barrier.

In its simplest form, the barrier comprises a movable gate which is urged toward a closed position. The gate serves to hinder the exit of the shredded strips and to confine the strips into a partially jammed state. As additional amounts of sheet material are fed or pulled into the shredding device, the expelling force of the shredding device forces the shredded strips into the confined area. Once the pressure forcing the jammed strips into the confined area overcomes the means for urging the gate into a closed position, the gate is urged open to allow a portion of the folded and crimped strips to escape.

Various methods and apparatus may be used to urge the gate toward its closed position and thereby retain the shredded strips within the confined area. For example, a weighted, hinged gate may be used. Other embodiments include the use of a pivotal gate which is urged toward its closed position by a spring or by a hydraulic or pneumatic piston.

Once the folded and crimped strips of sheet material are formed, the strips may be deposited within a receiving bin.

Alternatively, upon leaving a confined area, located immediately adjacent to the cutting blades, the compressed state of the folded and crimped strips may be maintained by forcing the strips to travel through a confined conduit. A second cutting device or shearing device may be located at some point along the length of the confined conduit or at the end thereof. The shearing device may be engaged to cut or shear the compacted, folded and crimped strips into segments.

Continued insertion of additional lengths of sheet material into the shredding device at a regulated rate naturally causes the folded strips to exit the shredding device at a similar regulated rate. If the strips are passed through the confined conduit and a shearing device is used, the shearing device may be activated at preselectable time intervals to shear, cut, or dissect the compressed, crimped strips traveling within the confined conduit into various segment lengths. This process enables the formation of crimped strips of material having any desired length from 100 foot lengths or greater to segments of one or two inches or smaller.

If a plurality of layers of sheet material are passed through the shredding device at one time, the shearing device forces each layer against an adjacent layer with a tremendous force. This force is necessary to cause the multiple layers of sheet material to sheer. Such compression, however, has an added benefit of sealing together or partially bonding the sheared ends of the juxtaposed and sheared strips. The bonding of each overlapping layer of sheet material to the proximately juxtaposed sheet material assists in maintaining the structural integrity the interlocking folded and crimped strips. Thus, a plurality of layered, shredded, folded and crimped strips of sheet material may be cut into short segments that are bonded at each terminal end thereof. These shorter segments serve very well to replace the use of styrofoam peanuts. Such shorter segments may also be used in existing gravity feed systems.

Longer lengths of the shredded, folded and crimped strips may be used for decorative effects at parties and/or window or room displays.

The longer lengths of the folded strips may also be used as bulk padding and packing material. When so used, the object to be protected may be liberally and literally wrapped within multiple lengths of interconnecting and interlocking folded and crimped, shredded strips.

Because the ridges of the paper strips interlock with one another, the strips hold their form and greatly increase the volume of space they occupy. Thus, the use of a smaller amount of paper is required to protect a particularly packaged object. The shock absorbency of the packing material is also substantially increased, since the impact of a blow is disbursed throughout each interacting ridge or web of the interconnecting folded strips. The folded and crimped status of the strips of the present invention allows for a substantially greater degree of interlocking effect and shock absorbency than do the kinked strips described in U.S. Pat. Nos. 2,621,567; 2,686,466; and 2,770,302.

If paper sheet material is used, the longer lengths of crimped, shredded strips may be placed within a retainer bin or hopper and a selected amount of bulk packaging material may be torn therefrom. This enables an operator to use an exact amount of desired packaging material, and thereby reduce waste.

Another important, added benefit of the present invention is the ability to use a variety of colors in the production of the shredded, folded and crimped strips. This enables the inventor to produce bulk packaging material of the present invention having the chosen colors of a particular store, company, or corporation. This is accomplished by simply using a sheet material having the desired color.

A combination of colors may also be used. Two or more differently colored sheets of material may be passed into the shredding machine to produce a variety of color combinations. The only limiting factor is the capacity of the shredding machine. For example, a first percentage of one color (such as 23% of dark blue) and a second percentage of another color (such as 77% of light blue) may be used. Thus, folded and crimped strips of packaging material may be produced with any number of colored sheet material combinations.

Printed, embossed, or any other means of identification may also be affixed to the sheet material which is shredded. Preferably, such printing locates the printed matter longitudinally along each length of shredded strip. Thus, a store, company or corporation may have its name, logo, trademark, or other subject matter, listed along each individually crimped strip.

Another important benefit is that recyclable, biodegradable sheet material may be used. By using pulp materials, such as paper and/or cardboard which breakdown and decompose quickly, the detriment to the environment by disposal of such material is minimized.

Depending upon the composition of the sheet material, the environment may even be enhanced by the discarding of such packaging material. For example, fertilizers or other beneficial additives may be incorporated into the sheet material. These benefits are in stark contrast to the damage caused by the disposal of styrofoam peanuts.

Existing apparatus and methods for packaging food products often cause substantial damage to the very products they are intended to protect. For example, existing apparatus and method for packaging flash frozen fish often cause scarring to appear on the fish. This difficulty is greatly overcome by the present invention because when the folded and crimped strips of the present invention are made from paper and are exposed to moisture, the folded strips conform to the contour of the object being packaged. This provides a more uniform and larger support framework for the object and scarring is eliminated, or at least substantially reduced.

Edible sheet material and sheet material which has been approved by the U.S. Food and Drug Administration (FDA) for use in packaging edible, or at least consumable, products may also be used. Thus, the wholesale and retail food industries are now provided with apparatus and methods for packaging food products which have been hence unavailable.

Additional uses for the crimped sheet material include using it a bulk material for starting worm composts and/or animal bedding.

The apparatus which produces such a universal bulk packaging material is inexpensive, and is easily manufactured. Operation of the apparatus is also extremely simplistic and may be accomplished by an unskilled worker.

The various objects of the invention are also provided by a preferred embodiment thereof including a method of producing a packing product comprising the steps of: feeding at least one sheet of material in a first direction; cutting the at least one sheet of material into a plurality of strip means; the cutting being performed by rotating two mats of alternating, overlapping cutting discs; the feeding of the at least one sheet of material being between the two sets of cutting discs; advancing each of the strip means by the rotating of at least an outer surface of a corresponding one to the cutting discs as the outer surface moves in the first direction; restricting each strip means from continued advancing in the first direction; and sequentially folding each strip means by the restricting in opposition to the advancing.

The sequential folding can occur adjacent the outer surface of the corresponding one of the cutting discs in a first of the two sets and between adjacent cutting discs in a second of the two sets. The sequential folding is against a natural resilience of the material of the strip means.

The sequential folding produces a plurality of folds of the strip means with adjacent folds being in opposite directions. The sequential folding of the plurality of folds is against natural resilience of the material to produce biasing at each of the folds tending to separate adjacent longitudinal portions of the strip means which are adjacent to each fold. The sequential folding of each strip means produces a longitudinally compressed strip means. The method further includes primarily collecting a plurality of the longitudinally compressed strip means between the two sets of cutting discs after the cutting and sequential folding. The method further includes additional collecting of an additional plurality of the longitudinally compressed strip means in a discharge chute remote from the two sets of cutting discs. The additional collecting produces resistance to movement of the plurality of longitudinally compressed strip means from the collecting and the collecting of the longitudinally compressed strip means causes the restricting of each strip means to cause the sequential folding.

The feeding includes simultaneously feeding a plurality of the sheets of material, the cutting of each strip means produces layers of strips of the material in the strip means, and the sequential folding causes substantially aligned folds of the plurality of folds respectively in each strip of the layers of strips.

The method includes the feeding which includes directing the material from a roll toward the two sets of cutting discs and transversely cutting the material in a direction which is transverse to the first direction to provide each of the at least one sheet of material prior to the cutting. The directing includes simultaneously directing a plurality of layers of the material and the transversely cutting forms a plurality of sheets of the material for the cutting.

The various objects are also provided by apparatus for producing a packing product comprising: means for feeding at least one sheet of material in a first direction; means for cutting the at least one sheet of material into a plurality of strip means; the means for cutting including two rotating sets of alternating, overlapping cutting discs; the means for feeding including means for directing the at least one sheet of material between the two rotating sets of cutting discs; means for restricting each of the strip means formed by the means for cutting; and the means for restricting for causing sequential folding of each strip means.

The means for feeding can include means for initially directing the material from a supply of the material and means for transversely cutting the material to form the at least one sheet of material. The means for feeding can be for feeding a plurality of layers of the material in the at least one sheet of material. Each of the cutting discs can include a cylindrical outer surface.

The preferred means for cutting includes a plurality of combers, each of the combers of the plurality being respectively aligned with each of the cutting discs, each comber having a facing end which is adjacent the strip means after formation thereof by the means for cutting, and the facing ends of the combers defining an area of passage of the strip means through the means for cutting. The facing ends of the combers can be substantially parallel.

The means for restricting each strip means includes a discharge chute extending from the means for cutting. apparatus can further include means for adjusting the means for restricting each strip means. The discharge chute can include wall means and the means for adjusting can include means for angularly adjusting the wall means of the discharge chute. The combers can include extensions for directing each strip means substantially in the first direction into an interior of the discharge chute.

Still further, the objects o