SPECIFICATION

BACKGROUND

[0001] The present disclosure is in the technical field of cushioning using converted sheet materials. More particularly, the present disclosure is directed to molding shaped converted sheet materials into molded cushioning products.

[0002] Cushioning objects for shipment to prevent damage is well known. Many forms of cushioning have been developed and used with varying degrees of success. One of the many challenges to cushioning is that objects come in many different sizes and shapes. Being able to provide proper cushioning for many objects of varying sizes and shapes is a significant challenge. Loose fill materials, such as foam peanuts, have been used in the past. However, packing objects for shipment using loose fill requires skill and judgment that not all packers have. Additionally, loose fill materials have been deemed poor for the environment because they tend not to be recyclable and they are rarely reused by shipping recipients. Wrapping materials, such as paper, foam sheeting, air cellular sheeting, and the like, have been used as well. However, wrapping of objects in sheet materials to provide proper protection and void fill can be labor-intensive and require a high degree of skill by the packer.

[0003] Machines have been developed to convert sheet materials from two-dimensional sheets into three-dimensional pads. For example, the PROPAD paper cushioning systems and the FASFIL paper void-fill systems offered by Sealed Air Corporation of Charlotte, NC, convert kraft paper from either a roll or a fanfolded stack into a pad that can be inserted into a shipping container to provide cushioning and/or void fill. Other examples are described in U.S. Patent Nos. 8,419,605 and 8,920,299, and in U.S. Patent Application No. 16/990,217, the contents of each of which are hereby incorporated by reference in their entirety. These systems typically provide linear feeds of converted sheet material that can be cut into pads. The material choice for these machines is typically fiber-based, such as kraft paper, which can be easily recycled and is considered more environmentally -friendly than many other types of cushioning and void-fill materials. However, sheet material conversion machines do not provide customized shapes or sizes that can help in the proper packaging of objects.

[0004] Foam-in-place packaging solutions have also been developed that provide highly- customizable and easy-to-pack packing material. For example, foam-in-bag systems (such as INSTAPAK foam-in-bag machines offered by Sealed Air Corporation of Charlotte, NC) dispense chemical precursors into a bag and close the bag while the chemical precursors react to form a lightweight foam. One particularly helpful benefit is that the foam will expand during the foaming process so that grows to conform around the object that is being packaged and fill the space between the object and the shipping container. Once the foam cures, it remains in place around the object. However, the cured foam is not recyclable and is unlikely to be reused because the foam was formed uniquely for that single shipment.

[0005] It would be advantageous for a packing material solution that provides the flexibility and ease of packaging as foam-in-place solutions while providing the recyclability of converted-sheet-material solutions.

SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In a first embodiment, a method includes providing a shaped converted sheet material. The shaped converted material comprises a sheet material that has been converted from a two-dimensional form into a three-dimensional form and then shaped into a non-linear shape. The method further includes molding the shaped converted sheet material from the non-linear shape into a molded cushioning product. The molding includes applying a compressive force to the non-linear shape of the shaped converted sheet material. The molded cushioning product is capable of being positioned in a container between the container and an object in the container to provide cushioning for the object. [0008] In a second embodiment, the providing of the first embodiment includes shaping the converted sheet material from the three-dimensional form into the non-linear shape.

[0009] In a third embodiment, the providing of the second embodiment further includes converting the sheet material from the two-dimensional form into the three-dimensional form before shaping the converted sheet material from the three-dimensional form into the non linear shape.

[0010] In a fourth embodiment, the molding of any of the previous embodiments includes applying a compressive force to the non-linear shape of the shaped converted sheet material between a positive mold portion and a negative mold portion.

[0011] In a fifth embodiment, the negative mold portion of the fourth embodiment is different from the container. The method further includes after applying the compressive force, removing the molded cushioning product from the negative mold portion and placing the molded cushioning product into the container.

[0012] In a sixth embodiment, the molded cushioning product of the fifth embodiment is one of a plurality of molded cushioning products placed in the container.

[0013] In a seventh embodiment, each of the plurality of molded cushioning products of the sixth embodiment includes a cavity that is substantially opposite of a portion of the object.

[0014] In an eighth embodiment, at least two of the plurality of molded cushioning products of any of the sixth or seventh embodiments have at least one of a different shape or a different size.

[0015] In a ninth embodiment, the container of the fourth embodiment is the negative mold portion. The method further includes, after applying the compressive force, removing the positive mold portion from the container and placing the object in the container with at least a portion of the object on the molded cushioning product.

[0016] In a tenth embodiment, the three-dimensional form of the shaped converted sheet material of any of the preceding embodiments is a coil having elongated sides with rounded ends. [0017] In an eleventh embodiment, the molding of the tenth embodiment includes applying the compressive force to the elongated sides such that the molded cushioning product has an inside bend along one of the elongated sides.

[0018] In a twelfth embodiment, the method of the eleventh embodiment further includes placing the molded cushioning product against the object with the inside bend of the molded cushioning product placed along an edge of the object.

[0019] In a thirteenth embodiment, the three-dimensional form of the shaped converted sheet material of any of the first to ninth embodiments is a triangular coil.

[0020] In a fourteenth embodiment, the molding of the thirteenth embodiment includes applying a compressive force to the non-linear shape of the shaped converted sheet material between a positive mold portion and a negative mold portion, the positive mold portion has a tetrahedral protrusion, and the negative mold portion has a tetrahedral cavity.

[0021] In a fifteenth embodiment, the method of the fourteenth embodiment further includes placing the molded cushioning product against a comer of the object with a cavity in the molded cushioning product formed by the tetrahedral protrusion abutting the comer of the object.

[0022] In a sixteenth embodiment, the molding of the shaped converted sheet material into the molded cushioning product of any of the previous embodiments includes forming a cavity in the molded cushioning product that has a shape corresponding to at least a portion of the object.

[0023] In a seventeenth embodiment, the method of the first embodiment further includes fixedly coupling a covering to an outside surface of the molded cushioning product.

[0024] In an eighteenth embodiment, the fixedly coupling of the seventeenth embodiment occurs while the shaped converted sheet material is molded from the non-linear shape into the molded cushioning product.

[0025] In a nineteenth embodiment, the method of the seventeenth embodiment further includes converting the covering from a flat configuration to a three-dimensional configuration prior to fixedly coupling the covering to the outside surface of the molded cushioning product. [0026] In a twentieth embodiment, the method of the nineteenth embodiment further includes applying a coupling agent to the covering after converting the covering from the flat configuration to the three-dimensional configuration and before fixedly coupling the covering to the outside surface of the molded cushioning product.

[0027] In a twenty first embodiment, the covering of the nineteenth embodiment is made from a single sheet material that includes a plurality of sides separated by a plurality of fold lines.

[0028] In a twenty second embodiment, a cushioning product includes a shaped converted sheet material. The shaped converted material comprises a sheet material that has been converted from a two-dimensional form into a three-dimensional form and then shaped into a non-linear shape. The cushioning product further includes a molded formation in the shaped converted sheet material. The molded formation is at least one of a protrusion or a cavity formed by molding the non-linear shape of the shaped converted sheet material into a molded cushioning product by applying a compressive force to the non-linear shape of the shaped converted sheet material. The molded cushioning product is capable of being positioned in a container between the container and an object in the container to provide cushioning for the object.

[0029] In a twenty third embodiment, the three-dimensional form of the shaped converted sheet material of the twenty second embodiment is a coil having elongated sides with rounded ends.

[0030] In a twenty fourth embodiment, the molded cushioning product of the twenty third embodiment has an inside bend along one of the elongated sides.

[0031] In a twenty fifth embodiment, the three-dimensional form of the shaped converted sheet material of the twenty second embodiment is a triangular coil.

[0032] In a twenty sixth embodiment, the at least one of the protrusion or the cavity of the twenty fifth embodiment includes at least one of a tetrahedral protrusion and a tetrahedral cavity.

[0033] In a twenty seventh embodiment, an apparatus is configured to fanfold converted sheet material. The converted sheet material has been converted from a two-dimensional form into a three-dimensional form. The apparatus includes a feed of the converted sheet material, a first threaded shaft, and a second threaded shaft. The axes of the first and second threaded shafts are substantially parallel to each other. The apparatus further includes a directing mechanism configured to direct the feed of the converted sheet material altematingly between the first and second threaded shafts such that a series of folds are formed in the converted material with the series of folds altematingly being inserted between threads of the first threaded shaft and threads of the second threaded shaft. The first and second threaded shafts are configured to be rotated in concert to advance the folded converted material with the folds in the threads of the first and second shafts.

[0034] In a twenty eighth embodiment, the apparatus of the twenty seventh embodiment further includes a tape applicator located between the first and second threaded shafts. The tape applicator is configured to apply tape to the folded converted sheet material.

[0035] In a twenty ninth embodiment, the tape applicator of the twenty eight embodiment is configured to apply the tape to a top of the folded converted sheet material between the alternating folds.

[0036] In a thirtieth embodiment, the apparatus of the twenty ninth embodiment further includes a pressure application device configured to apply pressure to the top of the folded converted sheet material after the tape has been applied to the top of the folded converted sheet material.

[0037] In a thirty first embodiment, the feed of the converted sheet material of any of the twenty seventh to thirtieth embodiments includes a pivotable arm configured to advance the converted sheet material toward the first and second threaded shafts.

[0038] In a thirty second embodiment, the pivotable arm of the thirty first embodiment is configured to pivot between a first position and a second position. In the first position, the pivotable arm directs the feed of the converted sheet material toward the first threaded shaft as the converted sheet material is fed. In the second position, the pivotable arm directs the feed of the converted sheet material toward the second threaded shaft as the converted sheet material is fed.

[0039] In a thirty third embodiment, the apparatus of the thirty second embodiment further includes a first guide positioned to guide the converted sheet material from an end of the pivotable arm to the first threaded shaft when the pivotable arm is in the first position and a second guide positioned to guide the converted sheet material from the end of the pivotable arm to the second threaded shaft when the pivotable arm is in the second position.

BRIEF DESCRIPTION OF THE DRAWING

[0040] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0041] Figs. 1 A and IB depict front and side views, respectively, of an embodiment of an apparatus configured to shape converted sheet material, in accordance with the embodiments described herein;

[0042] Figs. 2A, 2B, and 2C depict front, side, and perspective views, respectively, of an embodiment of the apparatus shown in Figs. 1 A and IB shaping a feed of converted sheet material into a coil, in accordance with the embodiments described herein;

[0043] Fig. 2D depicts a perspective view of the coil formed in Figs. 2A to 2C after the coil has been removed from the base, in accordance with the embodiments described herein;

[0044] Fig. 2E depicts an embodiment of the coil shown in Fig. 2D with tape around the coil, in accordance with the embodiments described herein;

[0045] Figs. 3A, 3B, and 3C depict front, side, and perspective views, respectively, of another embodiment of the apparatus shown in Figs. 1 A and IB shaping the feed of converted sheet material into a coil that as a different shape from the coil shown in Fig. 2D, in accordance with the embodiments described herein;

[0046] Fig. 3D depicts a perspective view of the coil formed in Figs. 3A to 3C after the coil has been removed from the base, in accordance with the embodiments described herein;

[0047] Fig. 3E depicts an embodiment of the coil shown in Fig. 2D with tape around the coil, in accordance with the embodiments described herein;

[0048] Figs. 4A and 4B depict front and side views, respectively, of an embodiment of an apparatus configured to shape converted sheet material, in accordance with the embodiments described herein; [0049] Figs. 5A, 5B, and 5C depict front, side, and perspective views, respectively, of an embodiment of the apparatus shown in Figs. 4A and 4B shaping a feed of converted sheet material into a coil, in accordance with the embodiments described herein;

[0050] Fig. 5D depicts a perspective view of the coil formed in Figs. 5A to 5C after the coil has been removed from the base, in accordance with the embodiments described herein;

[0051] Figs. 6A and 6B depict front and side views, respectively, of an apparatus configured to shape converted sheet material by folding, in accordance with the embodiments described herein;

[0052] Figs. 7A to 7F depict front views of instances of an embodiment of a method of the apparatus shown in Figs. 6A and 6B shaping a feed of converted sheet material into a folded stack, in accordance with the embodiments described herein;

[0053] Figs. 8A and 8B depict front and side views, respectively, of the folded stack of the converted sheet material formed in Figs. 7A to 7F, in accordance with the embodiments described herein;

[0054] Fig. 8C depicts an embodiment of the folded stack shown in Figs. 8A and 8B with tape around the folded stack to restrain the folded stack in the folded shape, in accordance with the embodiments described herein;

[0055] Figs. 9A, 9B, and 9C depict front perspective, partial, and rear perspective views, respectively, of an apparatus configured to shape converted sheet material by folding, in accordance with the embodiments described herein;

[0056] Figs. 10A to IOC depict an embodiment of molding a shaped converted sheet material into a molded cushioning product, in accordance with the embodiments described herein;

[0057] Fig. 10D depicts a perspective view of an embodiment of an object being packaged by a combination of a shaped converted sheet material and the molded cushioning product formed in Figs. 10A to IOC, in accordance with the embodiments described herein;

[0058] Figs. 11A to 11C depict another embodiment of molding a shaped converted sheet material into a molded cushioning product, in accordance with the embodiments described herein; [0059] Fig. 1 ID depicts a perspective view of an embodiment of an object being packaged by the molded cushioning product formed in Figs. 11 A to 11C, in accordance with the embodiments described herein;

[0060] Figs. 12A and 12B depict embodiments of a molded cushioning product and an object, respectively, where the shaped converted sheet material is molded into a shape that is specific to the particular object, in accordance with the embodiments described herein;

[0061] Figs. 13A and 13B depict an embodiment of a molding system capable of molding multiple units of shaped converted sheet material, in accordance with the embodiments described herein;

[0062] Fig. 13C depicts a top view of an embodiment of a container that has molded cushioning products formed by the molding system shown in Figs. 13 A and 13B, in accordance with the embodiments described herein;

[0063] Fig. 13D depicts atop view of an embodiment of the container shown in Fig. 13C with an object placed therein and cushioned by the molded cushioning products, in accordance with the embodiments described herein;

[0064] Figs. 14A and 14B depict top and side views, respectively, of an embodiment of a shaped converted sheet material, in accordance with the embodiments described herein;

[0065] Figs. 14C and 14D depict top and side views, respectively, of an embodiment of a molded cushioning product formed from the shaped converted sheet material shown in Figs. 9A and 9B, in accordance with the embodiments described herein;

[0066] Figs. 14E and 14F depict top and side views, respectively, of an embodiment of a shaped converted sheet material placed next to the molded cushioning product shown in Figs. 14C and 14D, in accordance with the embodiments described herein;

[0067] Figs. 15A to 15D depict top views of instances of an embodiment of a method of packaging a container using a combination of units of the molded cushioning product shown in Figs. 14C to 14F and units of the shaped converted sheet material shown in Figs. 14E and 14F, in accordance with the embodiments described herein;

[0068] Figs 16Ato 16C depict various embodiments of molded cushions, including covered molded cushions, in accordance with the embodiments described herein; [0069] Figs 17A and 17B depict perspective and side views, respectively, of an embodiment of the molded cushion shown in Fig. 16C being used to cushion the comers of an object, in accordance with the embodiments described herein;

[0070] Figs 18A and 18B depict an upper-left perspective view and a lower-right perspective view, respectively, of an embodiment of molded cushions being used to cushion all of the comers of an object, in accordance with the embodiments described herein;

[0071] Fig. 18C depicts an embodiment of a shipping container with the molded cushions and the object from Figs. 18A and 18B located inside, in accordance with the embodiments described herein;

[0072] Figs 19A to 19F depict an embodiment of fixedly coupling a covering to a molded cushioning product at the time that the molded cushioning product is formed from shaped converted sheet material, in accordance with the embodiments described herein;

[0073] Figs 20A to 20H depict another embodiment of fixedly coupling a covering to a molded cushioning product at the time that the molded cushioning product is formed from shaped converted sheet material, in accordance with the embodiments described herein; and

[0074] Figs 21 A to 21C depict an embodiment of a covering configured to be fixedly coupled to a molded cushioning product to form a covered molded cushion, in accordance with the embodiments described herein.

DETAILED DESCRIPTION

[0075] The present disclosure describes embodiments of apparatuses and methods of shaping converted sheet material. As used herein, the term “converted sheet material” refers to a sheet material that has been converted from a two-dimensional form to a three-dimensional form. In some embodiments, the sheet material is a fiber-based sheet material, such as paper, kraft paper, paperboard, cardstock, or other sheet material. In other embodiments, the sheet material is a non-fiber-based sheet material, such as a plastic film, foam sheeting, or other sheet material. Prior to conversion, the sheet material can be in a two-dimensional form, such as a roll of the sheet material, a fan folded stack of the sheet material, or other lay-flat, two dimensional form. Conversion of the sheet material from the two-dimensional form to the three-dimensional form can include crumpling, folding, compressing, or otherwise deforming the sheet material until it forms a three-dimensional form, such as a pad. After conversion, the converted sheet material has a greater volume and lower density than the sheet material in the two-dimensional form. Examples of conversion systems that convert sheet material into converted sheet material includes the PROPAD paper cushioning systems and the FASFIL paper void-fill systems offered by Sealed Air Corporation of Charlotte, NC. Other examples are described in U.S. Patent Nos. 8,419,605 and 8,920,299, and in U.S. Patent Application No. 16/990,217, the contents of each of which are hereby incorporated by reference in their entirety.

[0076] Conversion systems typically produce a feed of the converted sheet material that is substantially linear. The linear feed of converted sheet material can be cut at desired locations to form pads of the converted sheet material. Such pads can be inserted into shipping containers as cushioning and/or void fill. In some cases, it would be advantageous for the converted sheet material to be in a nonlinear shape when placed in a shipping container. In some cases, packers can manually shape the converted sheet material (e.g., by bending or folding). In other cases, the shaping of converted sheet material can be performed by a machine that shapes the converted sheet material from a linear shape to a non-linear shape.

[0077] Figs. 1 A and IB depict front and side views, respectively, of an embodiment of an apparatus 100 configured to shape converted sheet material. The apparatus 100 includes a base 102. In the depicted embodiment the base 102 is circular and is configured to be rotated about an axis. For example, the base 102 can be coupled to a motor, an engine or other driving mechanism configured to rotate the base 102. The apparatus 100 includes a protrusion 110 and a protrusion 112 that extend from a surface of the base 102. In the depicted embodiment, each of the protrusions 110 and 112 includes two pins that extend from the surface of the base 102. In other embodiments, each of the protrusions 110 and 112 can include any number of pins (e.g., one or more) or any number of other types of protrusions. The protrusions 110 and 112 are configured to contact and shape a feed of converted sheet material, as discussed in greater detail below.

[0078] In some embodiments, at least one of the protrusions 110 and 112 is configured to be positioned at multiple positions with respect to one or more of the other of the protrusions 110 and 112 and the base 102. In the depicted embodiment, each of the protrusions 110 and 112 is configured to be positioned at multiple positions with respect to the other of the protrusions 110 and 112 and with respect to the base 102. For example, the protrusion 110 is located in a slot 120 in the base 102 and the protrusion 110 is configured to be positioned at multiple different locations within the slot 120 (e.g., the position of the protrusion 110 at one end of the slot 120 and the position indicated by the dashed lines at the other end of the slot 120). The protrusion 110 can be moved in a direction 130 within the slot 120. In the depicted embodiment, the direction 130 is a radial direction with respect to the base 102. Similarly, the protrusion 112 is located in a slot 122 in the base 102 and the protrusion 112 is configured to be positioned at multiple different locations within the slot 122 (e.g., the position of the protrusion 112 at one end of the slot 122 and the position indicated by the dashed lines at the other end of the slot 122). The protrusion 112 can be moved in a direction 132 within the slot 122. In the depicted embodiment, the direction 132 is a radial direction with respect to the base 102 and the direction 132 is substantially parallel to and on an opposite side of the axis of the base 102 from the direction 132.

[0079] The apparatus 100 can be used to shape converted sheet material into coils of a number of different sizes and shapes. Figs. 2A, 2B, and 2C depict front, side, and perspective views, respectively, of an embodiment of the apparatus 100 shaping a feed of converted sheet material 140 into a coil. In particular, Figs. 2A, 2B, and 2C depict the base 102 being rotated in a direction 104. The rotation of the base 102 in the direction 104 can be caused by a motor, an engine, or other driving mechanism that is coupled to the base 102. In some embodiments, an end of the converted sheet material 140 is restricted by the protrusions 110 and 112 while the base 102 is rotated in the direction 104. In the depicted embodiment, the end of the converted sheet material 140 is restricted between the two pins of the protrusion 110. In other embodiments, the converted sheet material 140 can be restricted by one or both of the protrusions 110 and 112 in a number of other ways.

[0080] In the depicted embodiment, the end of the converted sheet material 140 is held between the two pins of the protrusion 110. In some embodiments, the pins of a protrusion are configured to be moved away from and toward each other. For example, the pins of the protrusion 110 can be moved apart to enable the end of the converted sheet material 140 to be inserted between the pins and then the pins of the protrusion 110 can be moved together to pinch or grip the end of the converted sheet material 140. In some embodiments, the apparatus 100 includes a sensor configured to detect the insertion of the end of the converted sheet material 140 between the pins and then the pins of the protrusion 110, such as a physical switch or an optical eye. Similarly, in addition to or instead of the movability of the protrusion 110, the pins of the protrusion 112 can be configured to move away from and toward each other to pinch or grip the end of the converted sheet material 140.

[0081] As the base 102 is rotated, the converted sheet material 140 is formed into a coil 142 by the protrusions 110 and 112. In some embodiments, the converted sheet material 140 is a feed of the converted sheet material 140 that is fed toward the base 102 as the base 102 is rotated. For example, the converted sheet material 140 can be fed from directly from a conversion machine that converts sheet material into the converted sheet material 140 or from a stored supply of the converted sheet material 140. In the depicted embodiment, the protrusions 110 and 112 are positioned in the slots 120 and 122, respectively, near the center of the base 102. This positioning of the protrusions 110 and 112 causes the coil 142 to be formed in a substantially-circular shape. As discussed in greater detail below, the protrusions 110 and 112 can be positioned at other locations to create a coil having different shapes.

[0082] The base 102 can continue to be rotated until the coil 142 has been reached a desired size. Once the coil 142 has reached a particular size, the coil 142 can be removed from the base 102. Fig. 2D depicts a perspective view of the coil 142 after it has been removed from the base 102. In some embodiments, the coil 142 can be secured in a particular shape by tape, a strap, or other restraining mechanism. Fig. 2E depicts an embodiment of the coil 142 with tape 144 around the coil 142 to restrain the coil 142 in the substantially-circular shape.

[0083] Figs. 3A, 3B, and 3C depict front, side, and perspective views, respectively, of another embodiment of the apparatus 100 shaping the feed of converted sheet material 140 into a coil 146 that as a different shape from the coil 142. In particular, Figs. 3A, 3B, and 3C depict the base 102 being rotated in a direction 104 with the end of the converted sheet material 140 is restricted by the protrusions 110 and 112 while the base 102 is rotated in the direction 104. In the depicted embodiment, the protrusions 110 and 112 are positioned in the slots 120 and 122, respectively, away from the center of the base 102. This positioning of the protrusions 110 and 112 causes the coil 146 to be formed in a shape having elongated sides and rounded ends. [0084] The base 102 can continue to be rotated until the coil 146 has been reached a desired size. Once the coil 146 has reached a particular size, the coil 146 can be removed from the base 102. Fig. 3D depicts a perspective view of the coil 146 after it has been removed from the base 102. In some embodiments, the coil 146 can be secured in a particular shape by tape, a strap, or other restraining mechanism. Fig. 3E depicts an embodiment of the coil 146 with tape 148 around the coil 146 to restrain the coil 146 in the shape with the elongated sides and the rounded ends.

[0085] Figs. 4A and 4B depict front and side views, respectively, of an embodiment of an apparatus 200 configured to shape converted sheet material. The apparatus 200 includes a base 202. In the depicted embodiment the base 202 is circular and is configured to be rotated about an axis. For example, the base 202 can be coupled to a motor, an engine or other driving mechanism configured to rotate the base 202. The apparatus 200 includes a protrusion 210, a protrusion 212, and a protrusion 214 that extend from a surface of the base 202. In the depicted embodiment, each of the protrusions 210, 212, and 214 includes two pins that extend from the surface of the base 202. In other embodiments, each of the protrusions 210, 212, and 214 can include any number of pins (e.g., one or more) or any number of other types of protrusions. The protrusions 210, 212, and 214 are configured to contact and shape a feed of converted sheet material, as discussed in greater detail below.

[0086] In some embodiments, at least one of the protrusions 210, 212, and 214 is configured to be positioned at multiple positions with respect to one or more of the other of the protrusions 210, 212, and 214 and the base 202. In the depicted embodiment, each of the protrusions 210, 212, and 214 is configured to be positioned at multiple positions with respect to the others of the protrusions 210, 212, and 214 and with respect to the base 202. For example, the protrusion 210 is located in a slot 220 in the base 202 and the protrusion 210 is configured to be positioned at multiple different locations within the slot 220 (e.g., the position of the protrusion 210 at one end of the slot 220 and the position indicated by the dashed lines at the other end of the slot 220). The protrusion 210 can be moved in a direction 230 within the slot 220. In the depicted embodiment, the direction 230 is a radial direction with respect to the base 202. Similarly, the protrusion 212 is located in a slot 222 in the base 202 and the protrusion 212 is configured to be positioned at multiple different locations within the slot 222 (e.g., the position of the protrusion 212 at one end of the slot 222 and the position indicated by the dashed lines at the other end of the slot 222). The protrusion 212 can be moved in a direction 232 within the slot 222. In the depicted embodiment, the direction 232 is a radial direction with respect to the base 202. Also, the protrusion 214 is located in a slot 224 in the base 202 and the protrusion 214 is configured to be positioned at multiple different locations within the slot 224 (e.g., the position of the protrusion 214 at one end of the slot 224 and the position indicated by the dashed lines at the other end of the slot 224). The protrusion 214 can be moved in a direction 234 within the slot 224. In the depicted embodiment, the direction 234 is a radial direction with respect to the base 202. In the depicted embodiment, the directions 230, 232, and 234 are arrange substantially equidistantly around the axis of the base 202.

[0087] The apparatus 200 can be used to shape converted sheet material into coils of a number of different sizes and shapes. Figs. 5A, 5B, and 5C depict front, side, and perspective views, respectively, of an embodiment of the apparatus 200 shaping a feed of converted sheet material 240 into a coil. In particular, Figs. 5A, 5B, and 5C depict the base 202 being rotated in a direction 204. The rotation of the base 202 in the direction 204 can be caused by a motor, an engine, or other driving mechanism that is coupled to the base 202. In some embodiments, an end of the converted sheet material 240 is restricted by the protrusions 210, 212, and 214while the base 202 is rotated in the direction 204. In other embodiments, the converted sheet material 240 can be restricted by one more of the protrusions 210, 212, and 214 in a number of other ways.

[0088] In the depicted embodiment, the end of the converted sheet material 240 is held between the two pins of the protrusion 210. In some embodiments, the pins of a protrusion are configured to be moved away from and toward each other. For example, the pins of the protrusion 210 can be moved apart to enable the end of the converted sheet material 240 to be inserted between the pins and then the pins of the protrusion 210 can be moved together to pinch or grip the end of the converted sheet material 240. In some embodiments, the apparatus 200 includes a sensor configured to detect the insertion of the end of the converted sheet material 240 between the pins and then the pins of the protrusion 210, such as a physical switch or an optical eye. Similarly, in addition to or instead of the movability of the protrusion 210, the pins of the protrusion 212 and/or the pins of the protrusion 214 can be configured to move away from and toward each other to pinch or grip the end of the converted sheet material 240.

[0089] As the base 202 is rotated, the converted sheet material 240 is formed into a coil 242 by the protrusions 210 and 212. In some embodiments, the converted sheet material 240 is a feed of the converted sheet material 240 that is fed toward the base 202 as the base 202 is rotated. For example, the converted sheet material 240 can be fed from directly from a conversion machine that converts sheet material into the converted sheet material 240 or from a stored supply of the converted sheet material 240. In the depicted embodiment, the protrusions 210, 212, and 214 are positioned in the slots 220, 222, and 224, respectively, near the center of the base 202. This positioning of the protrusions 210, 212, and 214 causes the coil 242 to be formed in a substantially -triangular shape. As discussed in greater detail below, the protrusions 210, 212, and 214 can be positioned at other locations to create a coil having different shapes. In other embodiments, the protrusions 210, 212, and 214 may be positions farther away from the axis of the base 202 to form a larger coil. In other embodiments, the protrusions 210, 212, and 214 may not be located equidistantly from the axis of the base 202 so that the triangular shape of the coil is not the shape of an equilateral triangle.

[0090] The base 202 can continue to be rotated until the coil 242 has been reached a desired size. Once the coil 242 has reached a particular size, the coil 242 can be removed from the base 202. Fig. 5D depicts a perspective view of the coil 242 after it has been removed from the base 202. While not depicted in Fig. 5D, the coil 242, in some embodiments, can be secured in a particular shape by tape, a strap, or other restraining mechanism to maintain the coil 242 in the substantially -triangular shape.

[0091] In the embodiments described above, the apparatus 100 includes two protrusions 110 and 112 and the apparatus 200 includes three protrusions 210, 212, and 214. It will be apparent that other embodiments of apparatuses can have any number of such protrusions to form other shapes of coils. In some examples, embodiments of apparatuses may have four protrusions to form substantially -rectangular coils, or have five protrusions to form substantially-pentagonal coils, or have number of other protrusions.

[0092] In the embodiments described above, the apparatuses shape converted sheet material by coiling. In other embodiments, apparatuses can shape converted sheet material into other non-linear shapes. For example, the shaping of converted sheet material can be performed by an apparatus that shapes the converted sheet material by folding the converted sheet material.

[0093] Figs. 6A and 6B depict front and side views, respectively, of an apparatus 300 configured to shape converted sheet material by folding. The apparatus 300 includes a rotatable base 302. In the depicted embodiment the rotatable base 302 is circular and is configured to be rotated about an axis. For example, the rotatable base 302 can be coupled to a motor, an engine or other driving mechanism configured to rotate the rotatable base 302. The apparatus 300 includes a protrusion 310 and a protrusion 312 that extend from a surface of the rotatable base 302. In the depicted embodiment, each of the protrusions 310 and 312 includes a single pin that extends from the surface of the rotatable base 302. In other embodiments, each of the protrusions 310 and 312 can include any number of pins (e.g., one or more) or any number of other types of protrusions. The protrusions 310 and 312 are configured to contact and fold a feed of converted sheet material, as discussed in greater detail below. In the depicted embodiment, the rotatable base 302 is rotatably coupled to a nonrotatable base portion 306. The rotatable base 302 is configured to rotate with respect to the nonrotatable base portion 306 in a direction 304.

[0094] Figs. 7A to 7F depict front views of instances of an embodiment of a method of the apparatus 300 shaping a feed of converted sheet material 340 into a folded stack. In the first instance shown in Fig. 7A, the converted sheet material 340 is being fed from the right toward the rotatable base 302 and the protrusions 310 and 312. At the second instance shown in Fig. 7B, the converted sheet material 340 has been fed farther until the converted sheet material 340 has passed between the protrusions 310 and 312. With the converted sheet material 340 in the position shown in Fig. 7B, the rotatable base 302 can be rotated to cause the protrusions 310 and 312 to bend or fold the converted sheet material 340. In the third instance shown in Fig. 7C, the rotatable base 302 has been rotated in the direction 304 — clockwise from the view shown in Fig. 7C — until the protrusions 310 and 312 have bent or folded the converted sheet material 340.

[0095] At the fourth instance shown in Fig. 7D, the rotatable base 302 has been rotated in the direction 304 — counterclockwise from the view shown in Fig. 7D — until the protrusions 310 and 312 have returned to their original position. The converted sheet material 340 has also been fed farther to the left until the bent or folded end of the converted sheet material 340 is to the left of the protrusions 310 and 312. With the converted sheet material 340 in the position shown in Fig. 7D, the rotatable base 302 can be rotated to cause the protrusions 310 and 312 to bend or fold the converted sheet material 340. In the fifth instance shown in Fig. 7E, the rotatable base 302 has been rotated in the direction 304 — counterclockwise from the view shown in Fig. 7E — until the protrusions 310 and 312 have bent or folded the converted sheet material 340. In the depicted embodiment, the bend or fold made in Fig. 7E is the opposite direction of the bend or fold may in Fig. 7C.

[0096] After the protrusions 310 and 312 have bent or folded the converted sheet material 340 a desired number of times, the converted sheet material 340 can be severed to form a folded stack 342 of the converted sheet material 340. In the sixth instance shown in Fig. 7F, the folded stack 342 has been severed from the feed of the converted sheet material 340 and removed from the protrusions 310 and 312. Figs. 8A and 8B depict front and side views, respectively, of the folded stack 342 of the converted sheet material 340. In some embodiments, the folded stack 342 can be secured in a particular shape by tape, a strap, or other restraining mechanism. Fig. 8C depicts an embodiment of the folded stack 342 with tape 344 around the folded stack 342 to restrain the folded stack 342 in the folded shape.

[0097] Figs. 9A, 9B, and 9C depict front perspective, partial, and rear perspective views, respectively, of an apparatus 400 configured to shape converted sheet material by folding.

The apparatus 400 includes a threaded shaft 410 and a threaded shaft 412. In the depicted embodiment, the threaded shafts 410 and 412 are substantially parallel to each other. The threaded shafts 410 and 412 are configured to hold a series of folds formed in a feed of converted sheet material 440 with the series of folds altematingly being inserted between threads of the threaded shaft 410 and threads of the threaded shaft 412. The threaded shafts 410 and 412 are configured to be rotated in concert to advance the folded converted material with the folds in the threads of the first and second shafts.

[0098] In some embodiments, the feed of the converted sheet material 440 is shaped into a folded converted sheet material 442 by a feeding mechanism that directs the feed of the converted sheet material 440 alternately between the threaded shafts 410 and 412. In the depicted embodiment, the apparatus 400 includes a pivotable arm 414 configured to advance the converted sheet material 440 toward the threaded shafts 410 and 412. The pivotable arm 414 is configured to pivot between a first position and a second position. In the first position, the pivotable arm 414 directs the feed of the converted sheet material 440 toward the threaded shaft 410 as the converted sheet material 440 is fed. In the second position, the pivotable arm 414 directs the feed of the converted sheet material 440 toward the threaded shaft 412 as the converted sheet material 440 is fed. In the depicted embodiment, the apparatus 400 also includes a guide 416 and a guide 418. The guide 416 is positioned to guide the converted sheet material 440 from an end of the pivotable arm 414 to the threaded shaft 410 when the pivotable arm 414 is in the first position. The guide 418 is positioned to guide the converted sheet material 440 from an end of the pivotable arm 414 to the threaded shaft 412 when the pivotable arm 414 is in the second position.

[0099] The threaded shafts 410 and 412 hold the folded converted sheet material 442 as the folded converted sheet material 442 is advanced. In some embodiments, while the folded converted sheet material 442 is advanced by the threaded shafts 410 and 412, tape can be applied to the folded converted sheet material 442 so that the tape maintains the converted sheet material 440 in the form of the folded converted sheet material 442 after the folded converted sheet material 442 is no longer held by the threaded shafts 410 and 412. In the depicted embodiment, the apparatus 400 includes a tape applicator 420 located between the threaded shafts 410 and 412. The tape applicator 420 is configured to apply tap to the folded converted sheet material 442. In particular, the tape applicator 420 is configured to apply the tape to a top of the folded converted sheet material 442 between the alternating folds that are held by the threaded shafts 410 and 412. In some embodiments, the apparatus 400 includes pressure application device 422 configured to apply pressure to the top of the folded converted sheet material 442 after the tape has been applied to the top of the folded converted sheet material 442. In addition, the depicted embodiment of the apparatus 400 includes a restraining plate 424 that can be selectively located against an end of the folded converted sheet material 442 while the pressure application device 422 applies pressure to the top of the folded converted sheet material 442.

[0100] In some embodiments, the apparatus 400 is capable of severing portions of the folded converted sheet material 442 and holding severed portions of the folded converted sheet material 442. In the depicted embodiment, the apparatus 400 includes a severing device 426 located downstream of the threaded shafts 410 and 412 and upstream of the pressure application device 422. The severing device 426 can be any device capable of severing the folded converted sheet material 442, such as a blade, a knife, a rotary cutting element, and the like. In other embodiments, the severing device 426 can be located downstream of the pressure application device 422 or at any other location where the folded converted sheet material 442 is to be severed. The apparatus 400 also includes a holding bin 428 configured to hold the severed portions of the folded converted sheet material 442 after they are advanced downstream of the pressure application device 422. In some embodiments, the holding bin 428 is movable (e.g., a wheeled cart) configured to be moved after a number of severed portions of the folded converted sheet material 442 have been deposited into the holding bin 428.

[0101] Shaped converted sheet materials — including coiled converted sheet materials, folded converted sheet materials, and other forms of shaped converted sheet materials — can be used as cushioning and/or void fill in shipping packages. As noted above, one of the advantages of some kinds of packaging materials, such as foam-in-bag packaging materials, is that the packaging material is adaptable for packaging particular objects. However, converted sheet materials can be advantageous in particular situations, such as when the packaging material is to be easily recyclable. In some cases, it would be advantageous for the shaped converted sheet materials to be adapted for particular objects. In some embodiments, shaped converted sheet material can be molded into a molded cushioning product. In some embodiments, the shaped converted sheet material is in a non-linear shape and the shaped converted sheet material is molded by applying a compressive force to the non-linear shape of the shaped converted sheet material.

[0102] Figs. 10A to IOC depict an embodiment of molding a shaped converted sheet material into a molded cushioning product. Fig. 10A depicts a perspective view of a shaped converted sheet material 510. In the depicted embodiment, the shaped converted sheet material 510 is a coil with a shape having elongated sides and rounded ends, similar to the coil 146 shown in Fig. 3E. Fig. 10B depicts a molding system 500 capable of molding the shaped converted sheet material 510. The molding system 500 includes a negative mold portion 502 and a positive mold portion 504. The negative mold portion 502 has a cavity 506 and the positive mold portion 504 has a protrusion 508. In the depicted embodiment, the protrusion 508 of the positive mold portion 504 is a triangular prism protrusion and the cavity 506 of the negative mold portion 502 is a triangular prism cavity. In the depicted embodiment, the shaped converted sheet material 510 is placed between the negative mold portion 502 and a positive mold portion 504 with one elongated side oriented toward the negative mold portion 502 and the other elongated side oriented toward the positive mold portion 504. From the arrangement shown in Fig. 10B, the negative and positive mold portions 502 and 504 can be moved toward each other to applying a compressive force to shaped converted sheet material 510. Such a compressive force causes the shaped converted sheet material 510 to be molded into a molded cushioning product 512, which is depicted in Fig. IOC. As can be seen in Fig. IOC, the molded cushioning product 512 has an inside bend 514 along one of the elongated sides.

[0103] Fig. 10D depicts a perspective view of an embodiment of an object 520 being packaged by a combination of the shaped converted sheet material 510 and the molded cushioning product 512. In particular, the object 520 is being packaged with four units of the shaped converted sheet material 510 and four units of the molded cushioning product 512. Two units of the shaped converted sheet material 510 have been placed below the object 520 and two units of the shaped converted sheet material 510 have been placed above the object 520. Each of the four units of the molded cushioning product 512 has been placed against the object 520 with the inside bend 514 of the molded cushioning product 512 placed along an edge of the object 520. In particular, the inside bend 514 of the units of the molded cushioning product 512 have been placed along side edges of the object 520. The object 520, the units of the shaped converted sheet material 510, and the units of the molded cushioning product 512 can be placed inside of a shipping container (e.g., a corrugated box) in the orientation shown in Fig. 10D with the shaped converted sheet material 510 and the molded cushioning product 512 being positioned in the container between the container and the object 520. In this way, the units of the shaped converted sheet material 510 are arranged in the container to provide cushioning to the bottom and top of the object 520 and the units of the molded cushioning product 512 are arranged in the container to provide cushioning to the side edges of the object 520.

[0104] Figs. 11A to 11C depict another embodiment of molding a shaped converted sheet material into a molded cushioning product. Fig. 11 A depicts a perspective view of a shaped converted sheet material 610. In the depicted embodiment, the shaped converted sheet material 610 is a triangular coil, similar to the coil 242 shown in Fig. 5D. Fig. 1 IB depicts a molding system 600 capable of molding the shaped converted sheet material 610. The molding system 600 includes a negative mold portion 602 and a positive mold portion 604. The negative mold portion 602 has a cavity 606 and the positive mold portion 604 has a protrusion 608. In the depicted embodiment, the protrusion 608 of the positive mold portion 604 is a tetrahedral protrusion and the cavity 606 of the negative mold portion 602 is a tetrahedral cavity. In the depicted embodiment, the shaped converted sheet material 610 is placed between the negative mold portion 602 and a positive mold portion 604 with coiled sides of the shaped converted sheet material 610 oriented toward the negative mold portion 602 and the positive mold portion 604. From the arrangement shown in Fig. 1 IB, the negative and positive mold portions 602 and 604 can be moved toward each other to applying a compressive force to shaped converted sheet material 610. Such a compressive force causes the shaped converted sheet material 610 to be molded into a molded cushioning product 612, which is depicted in Fig. 11C. As can be seen in Fig. 11C, the molded cushioning product 612 has tetrahedral cavity 614 along one of the coiled sides of the molded cushioning product 612.

[0105] Fig. 1 ID depicts a perspective view of an embodiment of an object 620 being packaged by the molded cushioning product 612. In particular, the object 620 has the shape of a rectangular prism and the object 620 is being packaged with eight units of the molded cushioning product 612. Each of the eight units of the molded cushioning product 612 has been placed against the object 620 with the tetrahedral cavity 614 of the molded cushioning product 612 placed along a portion of the object 620. In particular, the tetrahedral cavity 614 of each of the units of the molded cushioning product 612 have been placed along a three- sided comer of the object 620. The object 620 and the units of the molded cushioning product 612 can be placed inside of a shipping container (e.g., a corrugated box) in the orientation shown in Fig. 1 ID with the molded cushioning product 612 being positioned in the container between the container and the object 620. In this way, the units of the molded cushioning product 612 are arranged in the container to provide cushioning to each of the comers of the object 620.

[0106] When viewing the embodiments shown in Figs. 10A to 1 ID, it will be apparent that converted sheet material can be molded into any desired shape to provide cushioning for an object in a shipping container. For example, the depicted embodiments of the molded cushioning products 512 and 612 can be used in place of non-recyclable materials. For example, molded cushioning products formed from shaped converted sheet material can be molded into any shape that extruded polystyrene foam has been shaped in past. However, when the shaped converted sheet material is formed from particular materials, such as fiber- based materials (e.g., kraft paper), the molded cushioning products formed from the shaped converted sheet material is easily recyclable while the earlier extruded polystyrene foam products (and products form from similar materials) are either not recyclable or not easily recyclable.

[0107] The examples of the molded cushioning products 512 and 612 above are molded into common shapes that can be used to provide cushioning for many different kinds of objects. For example, the molded cushioning product 512 can be used to cushion any side edge of a three-dimensional object and the molded cushioning product 612 can be used to cushion any side comer of a three-dimensional object. In other embodiments, shaped converted sheet material can be molded into shapes that are more specific to a particular object.

[0108] Figs. 12A and 12B depict embodiments of a molded cushioning product 712 and an object 720, respectively. In the depicted embodiment, the molded cushioning product 712 has been molded from a shaped converted sheet material having a substantially-circular coil shape, similar to the coil 142 shown in Fig. 2D. The molded cushioning product 712 has been molded so that the coiled side of the molded cushioning product 712 includes a cavity 714. In the depicted embodiment, the cavity 714 in the molded cushioning product 712 is a nonstandard shape that corresponds with a profile of the object 720. In this way, the object 720 can be oriented with respect to the molded cushioning product 712 in a way that allows the object 720 to be seated in the cavity 714 of the molded cushioning product 712. In some embodiments, the molded cushioning product 712 can be placed in a container, such as a corrugated box, and the object 720 can be seated in the cavity 714 of the molded cushioning product 712 inside of the container. In addition, another molded cushioning product can be placed over the object 720. In some examples, the other molded cushioning product can have a cavity corresponding to the profile of the other side of the object 720 so that the object is sandwiched between the molded cushioning product 712 and the other molded cushioning product. [0109] The embodiment shown in Figs. 12A and 12B show an example of specific shape of a cavity corresponding to an object that is formed in one molded cushioning product. In other embodiments, multiple molded cushioning products can have cavities formed therein that, when used together, form a shape corresponding to an object. Figs. 13A and 13B depict an embodiment of a molding system 800 capable of molding multiple units of shaped converted sheet material. The molding system 800 includes a negative mold portion 802 and a positive mold portion 804. The negative mold portion 802 has a cavity 806 and the positive mold portion 804 has a protrusion 808. In the depicted embodiment, the cavity 806 is capable of holding three units of a shaped converted sheet material that are substantially-circular coils.

In particular, the cavity 806 is capable of holding three substantially-circular coils with the coiled sides facing the bottom of the cavity 806 and the top of the cavity 806. In the depicted embodiment, the protrusion 808 of the positive mold portion 804 is contoured similar to half of a bottle. In the depicted embodiment, the three units of the shaped converted sheet material can be placed in the cavity 806 and the positive mold portion 804 with the protrusion 808 oriented toward the shaped converted sheet material units in the cavity 806. The positive mold portion 804 can then be forced into the cavity 806 to applying a compressive force to the units of shaped converted sheet material.

[0110] Fig. 13C depicts a top view of an embodiment of a container 810 that has a molded cushioning product 812, a molded cushioning product 814, and a molded cushioning product 816 located therein. The molded cushioning products 812, 814, and 816 have been molded in the molding system 800. In particular the molded cushioning products 812, 814, and 816 were formed from three units of shaped converted sheet material that are substantially- circular coils. The three units of shaped converted sheet material were molded in the molding system 800 to form a cavity 813 in the molded cushioning product 812, a cavity 815 in the molded cushioning product 814, and a cavity 817 in the molded cushioning product 816. When the molded cushioning products 812, 814, and 816 are placed in the container 810 in the orientation shown in Fig. 13C, the cavities 813, 815, and 817 collectively have a shape corresponding to a profile of a bottle.

[0111] Fig. 13D depicts atop view of an embodiment of the container 810 with an object 820 placed therein and cushioned by the molded cushioning products 812, 814, and 816. In particular, the object 820 is a bottle. The bottle has been oriented so that the bottle can be seated in the cavities 813, 815, and 817 to be cushioned by the molded cushioning products

812, 814, and 816. In some cases, approximately half of the bottle is seated in the cavities

813, 815, and 817 so that half of the bottle is cushioned by the molded cushioning products 812, 814, and 816. In such a case, another three units of similar shaped cushioning sheet material can be shaped by the molding system 800 and then placed in the container 810 with their cavities oriented downward onto the top of the bottle. In this way, both halves of the bottle can be cushioned by molded cushioning products.

[0112] As can be seen in the embodiment shown in Figs. 13C and 13D, it may be advantageous for some shipping containers to be packaged with multiple molded cushioning products that have different shapes and/or different sizes. The different shapes can include different shapes of the shaped converted sheet material from which the molded cushioning products are molded, different shapes of the molded formation (e.g., a protrusion or a cavity) formed by the molding, or any combination thereof. In other embodiments, it may be advantageous for some shipping containers to be packaged with a combination of shaped converted sheet materials and molded cushioning products. An example of using a combination of shaped converted sheet materials and molded cushioning products to package an object is depicted in Figs 14A to 15D.

[0113] Figs. 14A and 14B depict top and side views, respectively, of an embodiment of a shaped converted sheet material 900. In the depicted embodiment, the shaped converted sheet material 900 is a substantially-circular coil of converted sheet material. In some embodiments, the converted sheet material was formed from a fiber-based sheet material (e.g., kraft paper). Figs. 14C and 14D depict top and side views, respectively, of an embodiment of a molded cushioning product 910 formed from the shaped converted sheet material 900. The molded cushioning product 910 includes a cavity 912 formed by molding the shaped converted sheet material 900. In the depicted embodiment, the cavity 912 was formed by applying a compressive force on a portion 914 of the top coiled edge of the shaped converted sheet material 900. In the particular embodiment shown, the portion 914 is approximately one quarter of the top coiled edge. The cavity 912 also extends downward into the top coiled edge at a depth 916 so that the bottom of the cavity 912 is a height 918 above the bottom of the molded cushioning product 910. In some embodiments, the depth 916 is selected based on a dimension of an object to be packaged by the molded cushioning product 910, such a width of the object, a half of a width of the object, and the like.

[0114] Figs. 14E and 14F depict top and side views, respectively, of an embodiment of a shaped converted sheet material 920 placed next to the molded cushioning product 910. In the depicted embodiment, the shaped converted sheet material 920 is a substantially-circular coil of converted sheet material. In some embodiments, the converted sheet material was formed from a fiber-based sheet material (e.g., kraft paper). As can be seen in Fig. 14E, the shaped converted sheet material 920 is a smaller coil than the coil from which the molded cushioning product 910 was molded. As can be seen in Fig. 14F, the shaped converted sheet material 920 is shorter than the molded cushioning product 910. In the depicted embodiment, the height of the shaped converted sheet material 920 is similar to the height 918 of the bottom of the cavity 912 in the molded cushioning product 910.

[0115] The molded cushioning product 910 and the shaped converted sheet material 920 can be used together to provide cushioning for an object in a container and/or void fill insides of the container. Figs. 15A to 15D depict top views of instances of an embodiment of a method of packaging a container 930 using a combination of units of the molded cushioning product 910 and units of the shaped converted sheet material 920. In the instances shown in Figs.

15A to 15C, the top flaps of the container 930 are open; the top flaps of the container 930 are closed in the instance shown in Fig. 15D.

[0116] In the instance shown in Fig. 15A, four units of the molded cushioning product 910 and four units of the shaped converted sheet material 920 have been placed on the bottom of the container 930. The units of the molded cushioning product 910 have been placed in the comers of the container 930 with the top coiled edge (e.g., the coiled edge where the cavity 912 was formed) facing upward. The cavity 912 of each unit of the molded cushioning product 910 is oriented toward the middle of the container 930. In particular, the sides of the cavity 912 of each unit are substantially parallel to the sides of the container 930. The four units of the shaped converted sheet material 920 have been placed on the bottom of the container 930 in the gaps between the units of the molded cushioning product 910.

[0117] In the instance shown in Fig. 15B, an object 940 has been placed in the container 930 on the units of the molded cushioning product 910 and four units of the shaped converted sheet material 920. In particular, the object 940 has been placed on the bottoms of the cavities 912 of the units of the molded cushioning product 910 and on the tops of the shaped converted sheet material 920. Because the height of the shaped converted sheet material 920 is similar to the height 918 of the bottom of the cavity 912 in the units of the molded cushioning product 910, the bottoms of the cavities 912 and the tops of the shaped converted sheet material 920 collectively form a surface on which the object 940 can be placed. In addition, the sides of the object 940 are located with respect to the cavities 912 such that the sides of the object 940 are cushioned by the sides of the cavities 912. In some embodiments, the depth 916 of the cavities 912 is approximately one half of the thickness of the object 940 so that a portion of the object 940 rises above the tops of the units of the molded cushioning product 910.

[0118] In the instance shown in Fig. 15C, four additional units of the molded cushioning product 910 and four additional units of the shaped converted sheet material 920 have been placed in the container 930. In particular, the four additional units of the molded cushioning product 910 have been placed partially on the object 940. The top coiled edge of the four additional units have been oriented downward toward the object 940 so that the top comers of the object 940 are located in the cavities 912 of the four additional units of the molded cushioning product 910. In the areas of the top coiled edge outside of the cavities 912, the four additional units of the molded cushioning product 910 contact the four units of the molded cushioning product 910 that were placed on the bottom of the container 930. The four additional units of the shaped converted sheet material 920 have been placed on the top of the object 940 in the gaps between the four additional units of the molded cushioning product 910. In this arrangement, the object 940 is cushioned vertically by all eight units of the molded cushioning product 910 and all eight units of the shaped converted sheet material 920. In addition, the sides of the object 940 are cushioned by the sides of the cavities 912 of all eight units of the molded cushioning product 910.

[0119] In the instance shown in Fig. 15D, the top flaps of the container 930 have been closed. In some embodiments, the heights of the molded cushioning product 910 and the shaped converted sheet material 920 are selected such that the top flaps contact the four additional units of the molded cushioning product 910 and the four additional units of the shaped converted sheet material 920 when the tops flaps are closed. In this way, the units of the molded cushioning product 910 and the shaped converted sheet material 920 are firmly held in place inside of the container 930 with the object 940 sandwiches therebetween. In addition, when the molded cushioning product 910, the shaped converted sheet material 920, and the container 930 are formed from fiber-based material, the entire packaging surrounding the object 940 is easily recyclable. For example, when the object 940 is an item purchased by a consumer and the object 940 is shipped to the consumer in the container 930, the entire packaging surrounding the object 940 — including the molded cushioning product 910, the shaped converted sheet material 920, and the container 930 — can be curbside recyclable by the consumer.

[0120] Depicted in Figs. 16A to 16C are various embodiments of molded cushions, including covered molded cushions. Fig. 16A depicts a molded cushion 1010 that includes a molded cushioning product 1012. In the depicted embodiment, the molded cushion 1010 is uncovered with the outer surface of the molded cushion 1010 exposed. Fig. 16B depicts a molded cushion 1020 that includes a molded cushioning product (not visible) that is similar to the molded cushioning product 1012 of the molded cushion 1010. The molded cushion 1020 also includes a covering 1024 over the outer surface of the molded cushioning product. In the depicted embodiment, the covering 1024 is a light paper. In some embodiments, the light paper is kraft paper having a weight less than or equal to about 100 gsm (70 pounds), such as kraft paper having a weight of 60 gsm (40 pounds). Fig. 16C depicts a molded cushion 1030 that includes a molded cushioning product 1032 and a covering 1034 over the outer surface of the molded cushioning product. In the depicted embodiment, the covering 1034 is a heavy paper. In some embodiments, the heavy paper is a paper board having a weight greater than or equal to about 100 gsm (68 pounds), such as paper board having a weight of 150 gsm (100 pounds). In some embodiments, the covering 1024 can be any other type of fiber-based material, such as a corrugated material or a fabric material.

[0121] In embodiments where a molded cushion includes a covering over a molded cushioning product, the covering may be fixedly coupled to the molded cushioning product. For example, the covering may be coupled to the molded cushioning product by any type of coupling agent, such as adhesive, glue, tape, and the like. As discussed in examples below, the covering can be fixedly coupled to the molded cushioning product at the time that the molded cushioning product is formed from shaped converted sheet material. In the embodiments depicted in Figs. 16B and 16C, the coverings 1024 and 1034 are formed from paper that has been folded into a shape that corresponds with a shape of the outer surface of the molded cushioning products. The coverings 1024 and 1034 can be folded into the shapes shown in Figs. 16B and 16C either before the coverings 1024 and 1034 are fixedly coupled to the molded cushioning products or as part of the forming of the molded cushioning products.

[0122] There are a number of advantages provided with the use of a covering over a molded cushioning product in a molded cushion. In one example, the molded cushioning product tends to maintain its shape for longer periods of time when a covering is fixedly coupled to the molded cushioning product. In another example, having a covering over a molded cushioning product may increase the aesthetic appearance to consumers. In another example, information can be printed on the on the covering, such as advertising information, targeted information specific to a customer, instructional information about how to recycle the molded cushion and/or other packaging material, or any other information. In another example, the addition of the covering to the molded cushioning product may increase the cushioning strength of the molded cushion. In another example, the addition of the covering to the molded cushioning product may increase the ability for the molded cushion to be manipulated by automated machinery, such as robotic arms, automated packaging stations, and the like. Other advantages not mentioned herein are associated with the use of a covering over a molded cushioning product in a molded cushion.

[0123] Depicted in Figs. 17A and 17B are perspective and side views, respectively, of an embodiment of the molded cushion 1030 being used to cushion the comers of an object 1036. In the depicted embodiment, the molded cushion 1030 is placed on the comer of the object 1036 with the inner surfaces of the molded cushioning product 1032 located against portions of the three sides adjacent to the comer of the object 1036. The covering 1034 of the molded cushion 1030 is located on the outer surface of the molded cushioning product 1032. In the depicted embodiment, the molded cushion 1030 is located on the object 1036 such that each of the three sides of the covering 1034 is substantially parallel to one of the three sides adjacent to the comer of the object 1036. If the object 1036 and the molded cushion 1030 were placed in a shipping box, the three sides of the covering 1034 could be in contact with and/or parallel to three sides of the shipping box. In this configuration, the covering 1034 would aid in keeping the molded cushioning product 1032 properly oriented between the comer of the object 1036 and the comer of the shipping box. [0124] Figs. 18A and 18B depict an upper-left perspective view and a lower-right perspective view, respectively, of an embodiment of molded cushions being used to cushion all of the comers of an object. In the depicted embodiment, eight molded cushions 1110i, 11 IO2,

I I IO3, 111 O4, 111 O5, 11106, I I IO7, and 1110s (collectively, molded cushions 1110) are used to cushion the comers of an object 1120. Each of the molded cushions can be an uncovered molded cushion or a covered molded cushion, such as a molded cushion covered by a light paper covering, a molded cushion covered by a heavy paper covering, a molded cushion covered by a corrugated covering, or a molded cushion covered by a fabric covering. The object 1120 has the shape of a rectangular prism having six sides 1122i, 11222, 11223, 11224, 11225, and 1122b (collectively, sides 1122) that define eight comers. In the depicted embodiment, each of the molded cushions 1110 is located on one of the comers of the object 1120 and covers a portion of three of the sides 1122 that define the comer. For example, the molded cushion 11 lOi is located on the comer of the object 1120 that is defined by the sides 1122i, 11222, and 11223, and the molded cushion 11 lOi covers portions of the sides 1122i, 11222, and 11223.

[0125] In the arrangement shown in Figs. 18A and 18B, the molded cushions lllO and the object 1120 can be placed in a shipping container for shipment. Fig. 18C depicts an embodiment of the molded cushions 1110 and the object 1120 inside of a shipping container 1130. In the depicted embodiment, the shipping container 1130 is a corrugated cardboard box. In other embodiments, the shipping container 1130 can be a plastic container, a crate, a metal container, or any other container suitable for shipping or transporting objects. As can be seen in the depicted embodiment, the molded cushions 1110 are positioned between the comers of the object 1120 and the comers of the shipping container 1130. In the case that the molded cushions 1110 are covered molded cushions, the coverings on the outer sides of the molded cushions 1110 would be arranged substantially parallel to and/or be in contract with the inner sides of the shipping container 1130.

[0126] As discussed above, the covering of a covered molded cushion can be fixedly coupled to the molded cushioning product at the time that the molded cushioning product is formed from shaped converted sheet material. Figs. 19A to 19F depict an embodiment of fixedly coupling a covering to a molded cushioning product at the time that the molded cushioning product is formed from shaped converted sheet material. Fig. 19A depicts a portion of a molding system 1210 that includes a negative mold portion 1212. In the depicted embodiment, the negative mold portion 1212 has a substantially tetrahedral shape. In other embodiments, the negative mold portion 1212 can have any other shape. Fig. 19B depicts that a covering 1224 has been placed in the negative mold portion 1212. The covering 1224 has fold lines and a shape and size that allows the covering 1224 to conform to the shape of the negative mold portion 1212. In the instance shown in Fig. 19B, a coupling agent has been applied to the exposed sides of the covering 1224 (i.e., the sides that are facing upward in Fig. 19B). In the depicted embodiment, the coupling agent is a glue, but could be any other type of coupling agent (e.g., adhesive, tape) in other embodiments. The coupling agent can be applied to the covering 1224 either before or after the covering 1224 has been placed in the negative mold portion 1212.

[0127] In Fig. 19C, a shaped converted sheet material 1230 has been placed on the covering 1224 above the negative mold portion 1212. In the depicted embodiment, the shaped converted sheet material 1230 is a circular coil. In other embodiments, the shaped converted sheet material 1230 can have any other shape, such as a triangular coil, a coil having elongated sides and rounded ends, or any other shape. Fig. 19D depicts that a positive mold portion 1214 of the molding system 1210 has been placed over the shaped converted sheet material 1230 and forced toward the negative mold portion 1212. The forcing of the positive mold portion 1214 toward the negative mold portion 1212 has compressed the shaped converted sheet material 1230 to form the shaped converted sheet material 1230 into a molded cushioning product 1222. The forcing of the positive mold portion 1214 toward the negative mold portion 1212 has also caused the molded cushioning product 1222 to be compressed into the coupling agent on the covering 1224 to fixedly couple the molded cushioning product 1222 to the covering 1224.

[0128] In Fig. 19E, the positive mold portion 1214 has been removed from the molded cushioning product 1222. The covering 1224 is fixedly coupled to the molded cushioning product 1222 to form a covered molded cushion 1220. The side of the molded cushioning product 1222 visible in Fig. 19E has an indentation into which an object or a portion of an object (e.g., a comer) can be inserted. In Fig. 19F, the covered molded cushion 1220 has been removed from the molding system 1210 and flipped over so that the covering 1224 is visible. As can be seen in this figure, the covered molded cushion 1220 is similar to molded cushion 1030 and can be used to cushion an object similarly to the way that the molded cushions 1110 are used to cushion the object 1120 in Figs. 18A to 18C.

[0129] Figs. 20A to 20H depict another embodiment of fixedly coupling a covering to a molded cushioning product at the time that the molded cushioning product is formed from shaped converted sheet material. Fig. 20A depicts a portion of a molding system 1310 that includes a negative mold portion 1312 and a positive mold portion 1314. In the depicted embodiment, the negative mold portion 1312 and the positive mold portion 1314 have substantially elongated shapes. In other embodiments, the negative mold portion 1312 and the positive mold portion 1314 can have any other shape. Fig. 20A also shows a converted sheet material 1330 having an elongated shape placed next to the molding system 1310. Fig. 20B depicts that a covering 1324 has been placed in the negative mold portion 1312. The covering 1324 has fold lines and a shape and size that allows the covering 1324 to conform to the shape of the negative mold portion 1312. In the instance shown in Fig. 20B, a coupling agent is being applied to the exposed sides of the covering 1324 (i.e., the sides that are facing upward in Fig. 20B). In the depicted embodiment, the coupling agent is a glue, but could be any other type of coupling agent (e.g., adhesive, tape) in other embodiments. In other embodiments, the coupling agent can be applied to the covering 1324 before the covering 1324 has been placed in the negative mold portion 1312.

[0130] In Fig. 20C, the shaped converted sheet material 1330 has been placed on the covering 1324 above the negative mold portion 1312. In the depicted embodiment, the shaped converted sheet material 1330 is a coil having elongated sides and rounded ends. In other embodiments, the shaped converted sheet material 1330 can have any other shape, such as a round coil a triangular coil, or any other shape. Fig. 20D depicts that a positive mold portion 1314 of the molding system 1310 has been placed over the shaped converted sheet material 1330. In the depicted embodiment, the positive mold portion 1314 is rotatably coupled to the negative mold portion 1312. Portions of the negative and positive mold portions 1312 and 1314 are capable of translating with respect to the outer housing to compress the shaped converted sheet material 1330. In Fig. 20E, the positive mold portion 1314 is forced toward the negative mold portion 1312, which includes a portion of the positive mold portion 1314 being forced downward into the negative mold portion 1312. The forcing of the positive mold portion 1314 toward the negative mold portion 1312 has compressed the shaped converted sheet material 1330 to form the shaped converted sheet material 1330 into a molded cushioning product 1322. The forcing of the positive mold portion 1314 toward the negative mold portion 1312 has also caused the molded cushioning product 1322 to be compressed into the coupling agent on the covering 1324 to fixedly couple the molded cushioning product 1322 to the covering 1324. In Fig. 20F, the positive mold portion 1314 has been rotated back with respect to the negative mold portion 1312 and a portion of the negative mold portion 1312 being translated up out of the housing of the molding system 1310.

[0131] In Fig. 20G, the covering 1324 has been fixedly coupled to the molded cushioning product 1322 to form a covered molded cushion 1320. The covered molded cushion 1320 has been removed from the molding system 1310. The. The side of the molded cushioning product 1322 visible in Fig. 20E has an indentation into which an object or a portion of an object (e.g., a comer) can be inserted. In Fig. 20H, the covered molded cushion 1320 has been removed from the molding system 1310 and placed on the end of an object 1350. Another covered molding cushion 1340, which includes a molded cushioning product 1342 fixedly attached to a covering 1344, has been placed on the other end of the object 1350. In the depicted embodiment, the object 1350 is a laptop computer and the covered molded cushions 1320 and 1340 hold both ends of the laptop computer. In this arrangement, the object 1350 with the covered molded cushions 1320 and 1340 on the ends thereof can be placed in a shipping container or other container.

[0132] Figs. 21A to 21C depict an embodiment of a covering 1400 configured to be fixedly coupled to a molded cushioning product to form a covered molded cushion. Figs. 21A and 21B depict side views, respectively, of the covering 1400 when the covering 1400 is in a substantially flat configuration. Fig. 21C depicts a perspective view of the covering 1400 when the covering 1400 is in a three-dimensional configuration.

[0133] In the depicted embodiment, the covering 1400 includes three sides 1402, 1404, and 1406. In other embodiments, the covering 1400 could have any other number of sides. In the depicted embodiment, the sides 1402, 1404, and 1406 are formed from a single sheet of material with the sides 1402 and 1404 separated by a fold line 1408 and the sides 1404 and 1406 separated by a fold line 1410. As used herein, the term “fold line” includes any line of weakness in the sheet material that includes or improves the foldability of the sheet material, such as a crease, a crimp, a perforation, a cut, a score, a slit, or any other type of line of weakness.

[0134] In the depicted embodiment, the covering also includes a tab 1412. The tab 1412 is also formed from the single sheet of material and is separated from the side 1406 by a fold line 1414. The tab 1412 has been fixedly coupled to the side 1402. In some cases, the tab 1412 can be fixedly coupled to the side 1402 by a coupling agent (e.g., glue, adhesive, tape, etc.). In the depicted embodiment, the tab 1412 is fixedly coupled to the side 1402 such that the fold line 1414 is proximate to and substantially parallel to one of the edges of the side 1402. The side 1406 of covering 1400 also includes a fold line 1416. In the depicted embodiment, the fold line 1416 is substantially equidistant between the fold lines 1410 and 1414.

[0135] In the flat configuration shown in Figs. 21A and 21B, the covering 1400 is folded along the fold lines 1408 and 1416 and the fold lines 1410 and 1414 are substantially unfolded. In the configuration, the covering 1400 is substantially flat so that the covering 1400 can be stacked or otherwise stored with other similar coverings. In cases where information (e.g., targeted information) is printed on the covering 1400, it may be advantageous to print the information on the covering 1400 while the covering 1400 is in the flat configuration. From the flat configuration shown in Figs. 21 A and 21B to the three- dimensional configuration shown in Fig. 21 C. The conversion from the flat configuration to the three-dimensional configuration can be accomplished by unfolding the fold line 1416 and the fold lines 1408, 1410, and 1414 remain at least partially folded. In some cases, the fold lines 1408, 1410, and 1414 are folded at substantially similar angles and the fold line 1416 is unfolded until the side 1406 is substantially planar. This action of unfolding the converting the covering 1400 from the flat configuration to the three-dimensional configuration is sometimes referred to as “popping out” the covering 1400 as the unfolding of the fold line 1416 may feel like a “pop” to the person unfolding the covering 1400. With the covering 1400 in the three-dimensional configuration, the covering 1400 can be used to form a covered molded cushion, such as in the example shown in Figs. 19A to 19F.

[0136] For purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value.

[0137] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.