WO2025244687A1

WO2025244687A1 - Apparatus and method for dispensing an insulating dunnage product

Info

Publication number: WO2025244687A1
Application number: PCT/US2025/011533
Authority: WO
Inventors: Dennis J. Wagner; Robert C. Cheich; Brian J. STINARD; Thomas R. BAYT
Original assignee: Ranpak Corp
Current assignee: Ranpak Corp
Priority date: 2024-05-20
Filing date: 2025-01-14
Publication date: 2025-11-27
Anticipated expiration: 2026-11-20

Abstract

An insulated stacked dunnage liner-making apparatus includes a supply assembly configured to receive a stack of two or more dunnage pads and convey the stack in a downstream direction and a laminating assembly downstream of the supply assembly. The laminating assembly includes two cover sheet material supply supports, each configured to support a respective roll of liner cover sheet material. The laminating assembly is configured to feed the stack in the downstream direction, feed two layers of liner cover sheet material in the downstream direction from the respective rolls of liner cover sheet material supported on each of the two cover sheet material supply supports and laminate the stack in between the two layers of liner cover sheet material to form an insulated stacked dunnage liner.

Description

APPARATUS AND METHOD FOR DISPENSING AN INSULATING DUNNAGE PRODUCT

Field of the Invention

[0001] The present invention relates generally to the field of protective packaging material or dunnage, and more particularly to insulating dunnage products.

Background

[0002] A common insulated container for refrigerated shipping uses a molded polystyrene liner within a cardboard box. An ice pack or other cooling element may be placed in the container to keep the contents of the box cool during shipment. Additional layers of insulation, often covered by a plastic material, also may be used to separate the contents from direct contact with the cooling element and any moisture that may condense around the cooling element or nearby surfaces. Despite functioning well during actual shipment, the current refrigerated shipping system has several problems. For example, the polystyrene liners require a lot of space for storage at and before shipment to the packaging center. Polystyrene and plastic coverings also are not readily recyclable, produce hazardous materials when burned, and because plastic does not readily decompose, it has a persistent presence in the environment.

[0003] Paper-based insulating dunnage products have been used to provide adequate insulation properties to supplant some or all of the applications that currently require refrigerated shipment. In some applications, multi-layer paper-based insulating dunnage products may be used. Such materials used for cushioning or insulation often have negative qualities related to their appearance and handling. For example, rough and non-uniform edges or loose fibers may cause the dunnage product to have an unfinished and undesirable appearance. Additionally, the multiple layers can deflect or bend in non-uniform or unexpected ways, making their insertion into a container difficult and cumbersome.

Summary

[0004] The present disclosure provides an apparatus and method for making a paper-based insulating dunnage product that has a uniform covering, evenly sealed edges, and creases for folding the dunnage product, resulting in easier, more consistent, and more efficient insertion into and lining of containers. The apparatus and method provides a multi-layer insulating dunnage product with improved visual and aesthetic appeal, and with improved buckling points between all layers where the dunnage product will fold.

[0005] More specifically, the present disclosure provides a multi-layer and variable insulated stacked dunnage pad having two or more insulated dunnage pads in a stacked arrangement that is covered by a liner outer cover. Each of the two or more insulated dunnage pads within the insulated stacked dunnage pad may be formed of one or more sheets of paper deformed out of their planar state to form a plurality of air pockets when layered, wrapped within an outer cover. Paper is a renewable resource, and can be recycled, composted, or burned with fewer and less hazardous byproducts than plastic materials, such as polystyrene. The insulated dunnage pads and insulated stacked dunnage pad may be made of 100% curbside recyclable paper (e.g., kraft paper, tissue, and cellulose wadding), optionally with a moisture-resistant coating on the outer cover. The paper is relatively impermeable to air such that the dunnage product provides both cushioning and insulating properties. [0006] The apparatus and method described herein allows a customer the option to change the performance of the insulated stacked dunnage pad by adding or eliminating certain components or layers contained within the liner outer cover, and adjusting the dimensions (length, width, thickness, or a combination thereof) of the insulating material to ensure efficient use of space in the container to maintain the temperature in the container for the desired time. The insulating stacked dunnage pad can be produced on demand and with specific dimensions and cushioning and insulating properties, as needed. With this flexible system, a customer can tailor the insulating stacked dunnage pad for their specific needs, which can result in lower costs, longer insulating duration, less damage or a combination of all these.

[0007] An exemplary insulated stacked dunnage liner-making apparatus includes a supply assembly configured to receive a stack of two or more dunnage pads and convey the stack in a downstream direction and a laminating assembly downstream of the supply assembly. The laminating assembly includes two cover sheet material supply supports, each configured to support a respective roll of liner cover sheet material. The laminating assembly is configured to feed the stack in the downstream direction, feed two layers of liner cover sheet material in the downstream direction from the respective rolls of liner cover sheet material supported on each of the two cover sheet material supply supports and laminate the stack in between the two layers of liner cover sheet material to form an insulated stacked dunnage liner. [0008] In one or more embodiments of the dunnage liner-making apparatus, the two cover sheet material supply supports include a top cover sheet material supply support mounted above the supply assembly and configured to support a roll of top liner cover sheet material, and a bottom cover sheet material supply support mounted below the supply assembly and configured to support a roll of bottom liner cover sheet material.

[0009] In one or more embodiments of the dunnage liner-making apparatus, the stack of two or more dunnage pads includes at least one insulated dunnage pad having at least one layer of expandable slit sheet material in an expanded state. [0010] In one or more embodiments of the dunnage liner-making apparatus, the stack of two or more dunnage pads includes at least one wadding pad.

[0011] In one or more embodiments of the dunnage liner-making apparatus, the laminating assembly includes a conveyor assembly having a pair of top conveyors and a pair of bottom conveyors. [0012] In one or more embodiments of the dunnage liner-making apparatus, each of the pair of top conveyors includes a top drive belt and each of the pair of bottom conveyors includes a bottom drive belt.

[0013] In one or more embodiments of the dunnage liner-making apparatus, the laminating assembly further includes a lateral sealing assembly configured to seal lateral edges of the two layers of cover sheet material beyond lateral edges of the stack therebetween.

[0014] In one or more embodiments of the dunnage liner-making apparatus, the lateral sealing assembly includes band sealers and corresponding shoes configured to apply a downward force on the lateral edges of the two layers of liner cover sheet material against the band sealers.

[0015] In one or more embodiments of the dunnage liner-making apparatus, the laminating assembly further includes a dancer assembly configured to control tension applied to each of the two layers of liner cover sheet material.

[0016] In one or more embodiments of the dunnage liner-making apparatus, the insulated stacked dunnage liner further includes a sealing and cutting assembly downstream of the laminating assembly and configured to seal and cut a trailing end of the two layers of liner cover sheet material along a direction perpendicular to the downstream direction.

[0017] In one or more embodiments of the dunnage liner-making apparatus, the insulated stacked dunnage liner further includes a creasing assembly configured to crease the insulated stacked dunnage liner in one or more predetermined locations along the direction perpendicular to the downstream direction.

[0018] In one or more embodiments of the dunnage liner-making apparatus, the insulated stacked dunnage liner further includes an exit conveyor assembly configured to convey the insulated stacked dunnage liner further in the downstream direction for access by an operator. [0019] In one or more embodiments of the dunnage liner-making apparatus, the insulated stacked dunnage liner further includes a controller configured to control an operation of the insulated stacked dunnage liner-making apparatus.

[0020] In one or more embodiments of the dunnage liner-making apparatus, the supply assembly includes a stacking conveyor configured to receive the stack of two or more dunnage pads and convey the stack in the downstream direction.

[0021] In one or more embodiments of the dunnage liner-making apparatus, the supply assembly further includes a spacing conveyor downstream of the stacking conveyor, the spacing conveyor configured to maintain a gap between the stack and a succeeding stack of two or more dunnage pads in the supply assembly.

[0022] An exemplary method of making an insulated stacked dunnage liner includes the steps of supplying a stack of two or more dunnage pads, feeding the stack in a downstream direction, feeding two layers of liner cover sheet material in the downstream direction, and laminating the stack in between the two layers of liner cover sheet material to form an insulated stacked dunnage liner.

[0023] In one or more embodiments of the method, the step of laminating the stack in between the two layers of liner cover sheet material includes sealing lateral edges of the two layers of cover sheet material together beyond lateral edges of the stack to seal the stack therebetween.

[0024] In one or more embodiments of the method, the method further includes a step of sealing and cutting a trailing end of the two layers of liner cover sheet material along a direction perpendicular to the downstream direction.

[0025] In one or more embodiments of the method, the method further includes a step of conveying the insulated stacked dunnage liner in the downstream direction, after the step of cutting.

[0026] In one or more embodiments of the method, the method further includes a step of creasing the insulated stacked dunnage liner at one or more predetermined locations along a direction perpendicular to the downstream direction. [0027] The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail one or more illustrative embodiments of the invention. These embodiments, however, are but a few of the various ways in which the principles of the invention can be employed. Other objects, advantages and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.

Brief Description of the Drawings

[0028] FIG. 1 is a schematic illustration of an insulated stacked dunnage linermaking apparatus.

[0029] FIG. 2 is a cross-sectional view of an exemplary stacked insulated dunnage liner.

[0030] FIG. 3 is a cross-sectional view of another exemplary stacked insulated dunnage liner.

[0031] FIG. 4 is a perspective view of an insulated stacked dunnage linermaking apparatus.

[0032] FIG. 5 is a perspective view of a stacking conveyor of the insulated stacked dunnage liner-making apparatus of FIG. 4.

[0033] FIG. 6 is a schematic illustration of a stacking conveyor of an insulated stacked dunnage liner-making apparatus.

[0034] FIG. 7 is a perspective view of a spacing conveyor of an insulated stacked dunnage liner-making apparatus.

[0035] FIG. 8 is another perspective view of a spacing conveyor of an insulated stacked dunnage liner-making apparatus.

[0036] FIG. 9 is a perspective view of a laminating assembly of an insulated stacked dunnage liner-making apparatus.

[0037] FIG. 10 is a perspective view of a top movable dancer of a dancer assembly of an insulated stacked dunnage liner-making apparatus. [0038] FIG. 11 is a perspective view of spindles and web tensioning of an insulated stacked dunnage liner-making apparatus.

[0039] FIG 12 is another perspective view of spindles and web tensioning of an insulated stacked dunnage liner-making apparatus.

[0040] FIG. 13 is a cross-sectional view of a conveyor assembly of a laminating assembly of an insulated stacked dunnage liner-making apparatus.

[0041] FIG. 14 is a perspective view of a pair of bottom conveyors of a conveyor assembly of a laminating assembly of an insulated stacked dunnage linermaking apparatus.

[0042] FIG. 15 is a perspective view of the conveyor assembly of FIG. 13.

[0043] FIG. 16 is a perspective view of a sealing and cutting assembly of an insulated stacked dunnage liner-making apparatus.

[0044] FIG. 17 is a cross-sectional view of a sealing and cutting assembly of an insulated stacked dunnage liner-making apparatus.

[0045] FIG. 18 is a perspective view of an exit conveyor of an insulated stacked dunnage liner-making apparatus.

Detailed Description

[0046] An exemplary insulated stacked dunnage liner-making apparatus (“apparatus”) 10 for making a stacked insulated dunnage liner (“stacked liner”) 12 is schematically depicted in FIG. 1. The illustrated apparatus 10 includes a supply assembly 14 and a laminating assembly 16 downstream of the supply assembly 14 (as oriented by the downstream direction 18, the direction in which material moves through the apparatus 10). The supply assembly 14 includes a stacking conveyor 20 configured to receive a stack 22 of two or more dunnage pads (“stack”) and convey the stack 22 in the downstream direction 18. The stack 22 may include at least one insulated dunnage pad having an expandable slit sheet material in an expanded state, and/or at least one wadding pad (as described below). The supply assembly 14 also includes a spacing conveyor 24 downstream of the stacking conveyor 20 that is configured to maintain a gap between a preceding stack 22.1 and a succeeding stack 22.2 in the supply assembly 14.

[0047] The laminating assembly 16 receives the stack 22 from the supply assembly 14. The laminating assembly 16 includes two cover sheet material supply supports 26.1 , 26.2, each configured to support a respective roll of liner cover sheet material 28.1 , 28.2. Specifically, the two cover sheet material supply supports 26.1 , 26.2 include a top cover sheet material supply support 26.1 mounted above the supply assembly 14 and a bottom cover sheet material supply support 26.2 mounted below the supply assembly 14. The top cover sheet material supply support 26.1 is configured to support a roll of top liner cover sheet material 28.1 , and the bottom cover sheet material supply support 26.2 is configured to support a roll of bottom liner cover sheet material 28.2.

[0048] The laminating assembly 16 is configured to feed the stack 22 in the downstream direction 18 and feed two layers of liner cover sheet material 30.1 , 30.2 in the downstream direction 18 from the respective rolls of liner cover sheet material 28.1 , 28.2. Specifically, the laminating assembly 16 is configured to feed a top layer of liner cover sheet material (“top cover layer”) 30.1 from the roll of top liner cover sheet material 28.1 , and a bottom layer of liner cover sheet material (“bottom cover layer”) 30.2 from the roll of bottom liner cover sheet material 28.2. The top cover layer 30.1 and the bottom cover layer 30.2 can be collectively referred to as the “two cover layers” or the “cover layers” 30.1 , 30.2. The top cover layer 30.1 is guided over the top of the stack 22 in the downstream direction 18, and the bottom cover layer 30.2 is drawn under the stack 22 in the downstream direction 18. The laminating assembly 16 is configured to laminate the stack 22 in between the two layers of liner cover sheet material 30.1 , 30.2 to form the stacked liner 12, as depicted.

[0049] An exemplary insulated stacked liner 12 formed by the apparatus 10 of FIG. 1 is depicted in FIG. 2. The exemplary stacked liner 12 includes the stack 22 of two or more insulated dunnage pads 21 .1 , 21 .2, 21 .3. In the depicted embodiment, each insulated dunnage pad 21 .1 , 21 .2, 21 .3 includes at least one layer of expandable slit sheet material in the expanded state (“expanded slit sheet material”) 32.

[0050] When the at least one layer of expanded slit sheet material 32 in any of the insulated dunnage pads 21 .1 , 21 .2, 21 .3 includes two or more layers of expanded slit sheet material 32, the respective insulated dunnage pad 21 .1 , 21 .2, 21 .3 also includes at least one layer of separator sheet material 34. Each layer of separator sheet material 34 is layered in between two adjacent layers of expanded slit sheet material 32. In the embodiment depicted in FIG. 2, for example, the stacked liner 12 includes a stack 22 of three insulated dunnage pads 21 .1 , 21 .2, 21 .3. Each of the three insulated dunnage pads 21 .1 , 21 .2, 21 .3 includes four layers of expanded slit sheet material 32 and three layers of separator sheet material 34 alternately layered in between each layer of adjacent layers of expanded slit sheet material 32.

[0051] The one or more layers of expanded slit sheet material 32 and the at least one layer of separator sheet material 34, when present, are laminated between two layers of cover sheet material 36.1 , 36.2 to form the respective insulated dunnage pad 21 .1 , 21 .2, 21 .3. The stack 22 of two or more dunnage pads 21 .1 ,

21 .2, 21 .3 is laminated between the two cover layers 30.1 , 30.2 to form the stacked liner 12. It is understood, however, that the embodiment depicted in FIG. 2 is provided as a non-limiting example and that other numbers of insulated dunnage pads 21 .1 , 21 .2, 21 .3, each including various other numbers of layers of expanded slit sheet material 32 and respective layers of separator sheet material 34, as needed, may be provided.

[0052] Another exemplary stacked liner 12 formed by the apparatus 10 of FIG. 1 is depicted in FIG. 3. The depicted stacked liner 12 in FIG. 3 includes the stack 22 of one insulated dunnage pad 21 .1 having expanded slit sheet material 32, as described above, and three wadding pads 23.1 , 23.2, 23.3. Each wadding pad 23.1 ,

23.2, 23.3 includes a layer of a crumpled, embossed, or creped sheet material; typically has multiple layers; and those layers may be glued or otherwise secured together. The material of each wadding pad 23.1 , 23.2, 23.3 generally is not slit. The wadding pads 23.1 , 23.2, 23.3 may be surrounded by and/or encapsulated within a wadding cover 23.4, such as the wadding pad 23.3 shown in Fig. 3. The wadding pads 23.1 , 23.2, 23.3 may, however, be un-encapsulated, such as the wadding pads 23.1 and 23.2. It is understood, however, that the embodiment depicted in FIG. 3 is provided as a non-limiting example, and that other numbers of insulated dunnage pads 21 .1 having alternative layers and materials may be provided.

[0053] An exemplary material for the one or more layer of expanded slit sheet material 32, the at least one layer of separator sheet material 34, the two layers of cover sheet material 36.1 , 36.2, and the two cover layers 30.1 , 30.2 is paper, such as kraft paper. More particularly, the cover layers 30.1 , 30.2 can be a single ply of paper, making the insulated stacked dunnage pad 12 recyclable, reusable, and composed of a renewable resource. Suitable paper sheet material may have various basis weights, such as twenty-pound or forty-pound, for example. In some embodiments, the materials may be laminated or may include any other suitable material such as another paper, plastic sheets, metal foil, or any combination thereof, although this may impair the recyclability of the dunnage pads 21 .

[0054] The various layers 23.1-23.3, 32, 34, 36.1 , 36.2, 30.1 , 30.2 may all be made of the same or different materials and may have the same basis weights or different basis weights. For example, each of the at least one wadding pad 23.1 , 23.2, 23.3 may be a very light basis weight (e.g., 7 pound) crepe paper that is stacked to twenty-two layers thick, making the at least one wadding pad 23.1 , 23.2, 23.3 approximately 1 .27 centimeters (0.5 inches) thick. The at least one layer of separator sheet material 34 may have a basis weight of 15 pounds. The two layers of cover sheet material 36.1 , 36.2 may have the same dimensions as each other and may have a coating material included thereon to create a water and/or water vapor barrier sufficient to make the cover sheet material water resistant or waterproof. Additionally or alternatively, the two layers of liner cover sheet material 30.1 , 30.2 may have the same dimensions as each other and may have a coating material included thereon to create a water and/or water vapor barrier sufficient to make the cover sheet material water resistant or waterproof.

[0055] The at least one layer of expanded slit sheet material 32 and the at least one layer of separator sheet material 34 may each have different width and thickness dimensions in comparison to those dimensions of the two layers of cover sheet material 36.1 , 36.2, and in comparison to each other. For example, the at least one layer of expanded slit sheet material 32 may be narrower in width and thicker than the two layers of cover sheet material 36.1 , 36.2. Similarly, the at least one insulated dunnage pad 21 .1 , 21 .2, 21 .3 and at the least one wadding pad 23.1 , 23.2, 23.3 may each have different width and thickness dimensions in comparison to those dimensions of the two layers of liner cover sheet material 30.1 , 30.2, and in comparison to each other. For example, the stack 22 of the at least one insulated dunnage pads 21 .1 , 21 .2, 21 .3 may be narrower in width and thicker than the two layers of liner cover sheet material 30.1 , 30.2. The stacked liner 12, for example, may have a width in the range of approximately 20.32 centimeters (8 inches) to 45.72 centimeters (18 inches).

[0056] An exemplary slit sheet material for the one or more layer of expanded slit sheet material 32 has a plurality of longitudinally-spaced, transversely-extending rows of slits periodically formed in the sheet. The slits in each row typically are transversely offset from respective slits in adjacent rows. More particularly, the exemplary slit sheet material is configured to expand along a feed direction, transverse the direction of the slits along the row. In other words, under tension across the slit the sheet material adjacent an upstream side of the slit separates from the sheet material adjacent a downstream side of the slit so that the sheet material separates across the slit. Tension typically is applied longitudinally, in the direction of advancement, the feed direction, also typically referred to as the downstream direction. [0057] This exemplary slit sheet material is configured for expanding in one or more dimensions, also herein referred to as volume expansion or volumetric expansion. When the sheet material is stretched in a direction transverse the direction of the slits, perpendicular to a width dimension of the sheet material, the sheet material’s longitudinal length and its thickness increase, while the sheet material’s lateral width dimension decreases. The increased thickness as the sheet material is stretched longitudinally is caused at least in part by portions of the sheet material between the rows of slits rotating relative to the plane of the unexpanded sheet material. The thickness dimension extends in a normal direction relative to a face of the unexpanded sheet material. The normal direction is defined as generally orthogonal to the sheet material’s longitudinal length and also generally orthogonal to its width dimension, measured along a lateral extent between lateral edges of the sheet material.

[0058] The thickness of the slit sheet material can increase by an order of magnitude, or more, relative to its original thickness, when stretched in this manner. The expanded slit sheet material has an increased length and thickness and reduced width as compared to the unexpanded slit sheet material. This longitudinal stretching and increase in thickness results in a volumetrically expanded expandable sheet material.

[0059] Turning back to FIG. 1 , the apparatus 10 also may include a sealing and cutting assembly 38 downstream of the laminating assembly 16. The sealing and cutting assembly 38 is configured to seal and cut a trailing end of the cover layers 30.1 , 30.2 along a direction perpendicular to the downstream direction 18 to form the respective stacked liner 12. The apparatus 10 also may include a creasing assembly 40 for creasing the stacked liner 12 in one or more crease locations spaced along the length of the stacked liner 12. The creases extend across the width of the stacked liner 12, in the direction perpendicular to the downstream direction 18. Downstream of the creasing assembly 40, the apparatus 10 includes an exit conveyor 42 for conveying the stacked liner 12 further in the downstream direction 18 for access and retrieval by an operator.

[0060] The apparatus 10 also includes a controller 44 for generally coordinating and controlling the operation of the apparatus 10 and each of its component parts, described in detail below. The controller 44 may include a processor, a memory, and a program stored in the memory. The controller 44 may additionally include one or more input devices, such as for determining the desired length, composition and number of layers of each material of the desired resultant stacked liner 12, and one or more outputs, including outputs for controlling elements of the apparatus 10. The input devices can be connected to or include one or more of a touch screen display, a keyboard, a mouse, a scanner or sensor, a bar code reader, a radio frequency identification device (RFID) sensor, a microphone, a camera, etc. The controller 44 can be programmed to recognize the appropriate inputs that represent a desired length of the stacked liner 12 or identify a location to look up one or more available lengths.

[0061] With reference to FIGS. 4-18, the apparatus 10 will be described in more detail. As depicted in detail in FIG. 5, the stacking conveyor 20 includes a first conveyor belt 46 for conveying the stack 22 in the downstream direction 18. The stacking conveyor 20 also includes first adjustable side rails 48 vertically and perpendicularly extending from the first conveyor belt 46. Each of the first adjustable side rails 48 are adjustable relative to each other and the first conveyor belt 46 in a width direction 19, perpendicular to the downstream direction 18, for accommodating various widths of dunnage pads being conveyed on the first conveyor belt 46.

[0062] The first adjustable side rails 48 are configured to align the two or more dunnage pads in the stack 22 being conveyed on the conveyor belt 46. The first adjustable side rails 48 are mounted to a frame 45 of the apparatus 10. The frame 45 may be mounted on wheels 49. The first conveyor belt 46 includes a series of first conveyor rollers 47 that, in side elevational view, drive the first conveyor belt 46 clockwise to convey the stack 22 in the downstream direction 18. A first conveyor motor 47.1 , such as a servo motor, may be coupled to the respective first conveyor rollers 47 to drive the first conveyor rollers 47.

[0063] The stacking conveyor 20 of the apparatus 10 is configured to receive the stack 22. Specifically, for example, an operator may manually stack two or more dunnage pads on the first conveyor belt 46 to form the stack 22. Alternatively, as depicted in the schematic diagram of FIG. 6, a pad stacking machine 50 may automatically transfer and stack two or more dunnage pads on the first conveyor belt 46 to form the stack 22. In an embodiment, the pad stacking machine 50 may first form the stack 22 and then transfer the stack 22 onto the first conveyor belt 46. The two or more dunnage pads forming the stack 22 may be supplied directly from one or more dunnage liner-making apparatus 52. Additionally or alternatively, the two or more dunnage pads forming the stack 22 may be supplied from one or more bins 54 of pre-made dunnage pads. In any embodiment, once the desired number of two or more dunnage pads are stacked on the first conveyor belt 46 of the stacking conveyor 20 to form the stack 22, the first conveyor belt 46 is operated to start conveying the stack 22 in the downstream direction 18. For example, an operator may initialize the conveying step with the controller 44 once the stack 22 is formed on the first conveyor belt 46. The stack 22 will then advance toward the spacing conveyor 24 of the supply assembly 14.

[0064] With reference to FIG. 7, the spacing conveyor 24 includes a second conveyor belt 50 for receiving the stack 22 from the stacking conveyor 20, and further conveying the stack 22 in the downstream direction 18. The spacing conveyor 24 also includes second adjustable side rails 52 vertically and perpendicularly extending from the second conveyor belt 50. Each of the second adjustable side rails 52 is adjustable relative to each other and the second conveyor belt 50 in the width direction 19 for accommodating various widths of dunnage pads in the stack 22 and for aligning the two or more dunnage pads in the stack 22. The second adjustable side rails 52 are mounted to the frame 45 of the apparatus 10. The second conveyor belt 50 includes a series of second conveyor rollers 54 that, in side elevational view, drive the second conveyor belt 50 clockwise to convey the stack 22 in the downstream direction 18. A second conveyor motor, such as a servo motor, may be coupled to the respective second conveyor rollers 54 to drive the second conveyor rollers 54.

[0065] Between a downstream end of the first conveyor belt 46 of the stacking conveyor 20 and an upstream end of the second conveyor belt 50 of the spacing conveyor 24, the apparatus 10 may further include a pad sensor 43 mounted to the frame 45. The pad sensor 43 may be, for example, a reflective sensor. As the stack 22 passes the pad sensor 43 at the downstream end of the first conveyor belt 46 and at the upstream end of the second conveyor belt 50, the pad sensor 43 is configured to determine a length of the stack 22 in the downstream direction 18 (i.e., detect a downstream/leading end and upstream/trailing end of the stack 22 as it passes the pad sensor 43). For example, the pad sensor 43 may be a reflective sensor such that the stack 22 will interrupt a signal from the reflective sensor when a downstream/leading end of the stack 22 passes the pad sensor 43. The stack 22 will continue to interrupt the signal from the reflective sensor until an upstream/trailing end of the stack 22 passes the pad sensor 43. In another embodiment, the first conveyor motor 47.1 may have an encoder configured to read the length of the stack 22. The controller 44 is then configured to inform an operator of the detected stack length and, if the detected length is greater than expected (for example, if the two or more dunnage pads in the stack 22 are misaligned in the downstream direction 18), the operator may be notified to fix the alignment of the two or more dunnage pads in the stack 22.

[0066] The pad sensor 43 is therefore configured to identify when the stack 22 is leaving the stacking conveyor 20 and entering the spacing conveyor 24. When the stack 22 is completely off of the stacking conveyor 20, the stacking conveyor 20 may turn off while the spacing conveyor 24 continues to convey the stack 22 in the downstream direction 18. As depicted in FIG. 8, the spacing conveyor 24 may include a first spacing sensor 55 and a second spacing sensor 56, both mounted to the frame 45 between the spacing conveyor 24 and the laminating assembly 16. The first spacing sensor 55 and the second spacing sensor 56 may be mounted approximately 50mm apart, based on the desired spacing between the preceding and succeeding stacks 22.1 , 22.2, (FIG. 1 ) the second spacing sensor 56 being mounted downstream of the first spacing sensor 55. The spacing conveyor 24 continues to convey the stack 22, for example the preceding stack 22.1 , in the downstream direction 18 until the stack 22/22.1 reaches the first spacing sensor 55. At this point, if the stacking conveyor 20 does not receive another stack 22, for example the succeeding stack 22.2, thereon, the spacing conveyor 24 will stop and wait until the stacking conveyor 20 receives another stack 22/22.1 . Once the stacking conveyor 20 receives another stack 22/22.2 thereon, the spacing conveyor 24 will resume or continue conveying the preceding stack 22.1 to the second spacing sensor 56. Once the preceding stack 22.1 clears the first spacing sensor 55, the spacing conveyor 24 is free to adjust its speed to move the succeeding stack 22.2 toward the first spacing sensor 55. Then, once the preceding stack 22.1 clears the second spacing sensor 56, the spacing conveyor 24 can move again to maintain the proper spacing between the preceding and succeeding stacks 22.1 , 22.2. [0067] The second conveyor motor of the second conveyor belt 50 in the spacing conveyor 24 may include a precise encoder configured to control the position and speed of the stack 22 being conveyed on the second conveyor belt 50. That is, the second conveyor motor is configured to drive the second conveyor rollers 54 such that the second conveyor belt 50 conveys the preceding stack 22.1 sufficiently spaced apart from the succeeding stack 22.2. For example, the second conveyor motor may be configured to speed up, slow down or stop the second conveyor belt 50, as needed, to ensure sufficient spacing between the preceding stack 22.1 and the succeeding stack 22.2 as they are conveyed in the downstream direction 18 on the spacing conveyor 24. A sufficient gap between the preceding stack 22.1 and the succeeding stack 22.2 is needed to allow room for sealing and cutting the cover layers 30.1 , 30.2, as will be described later with reference to FIGS. 15 and 16. The second conveyor motor is therefore configured to drive the second conveyor belt 50 at a speed that closely matches a speed of the laminating assembly 16 to ensure the gap is maintained as the stacks 22.1 , 22.2 enter the laminating assembly 16.

[0068] As briefly mentioned, and depicted in detail in FIG. 7, the laminating assembly 16 includes two cover sheet material supply supports 26.1 , 26.2, each configured to support a respective roll of liner cover sheet material 28.1 , 28.2. Specifically, the two cover sheet material supply supports 26.1 , 26.2 include a top cover sheet material supply support 26.1 mounted above the supply assembly 14 and a bottom cover sheet material supply port 26.2 mounted below the supply assembly 14. The top cover sheet material supply support 26.1 is configured to support a roll of top liner cover sheet material 28.1 , and the bottom cover sheet material supply support 26.2 is configured to support a roll of bottom liner cover sheet material 28.2. Each of the two cover sheet material supply supports 26.1 , 26.2 may be in the form of spindles rotatably mounted to the frame 45. Specifically, as depicted in FIG. 7, the top cover sheet material supply support 26.1 is mounted on the frame 45 above the second conveyor belt 50 of the spacing conveyor 24 and the bottom cover sheet material supply support 26.2 is mounted on the frame 45 below the second conveyor belt 50 of the spacing conveyor 24. At least one of the top cover sheet material supply support 26.1 and the bottom cover sheet material supply support 26.2 may include a splice plate. For example, in the depicted embodiment, the bottom cover sheet material supply support 26.2 includes a splice plate 58 configured to aid in the splicing of one roll of bottom liner cover sheet material 28.2 to another when the roll of bottom liner cover sheet material 28.2 is used up.

[0069] The laminating assembly 16 is configured to feed the stack 22 in the downstream direction 18 from the second conveyor 50 of the spacing conveyor 24 along a feed path 25. The laminating assembly 16 is also configured to feed the cover layers 30.1 , 30.2 in the downstream direction 18 from the respective rolls of liner cover sheet material 28.1 , 28.2 supported on each of the two cover sheet material supply supports 26.1 , 26.2. The laminating assembly 16 is configured to layer the cover layers 30.1 , 30.2 above and below the stack 22, respectively, and to capture the stack 22 between the cover layers 30.1 , 30.2 to form the stacked pad 12 (i.e. laminate the stack 22 between the cover layers 30.1 , 30.2).

[0070] Turning to FIGS. 9-14, the laminating assembly 16 may include a dancer assembly 60 and a conveyor assembly 62. The dancer assembly 60 is configured to control a tension applied to each of the two cover layers 30.1 , 30.2, as they are pulled from the respective rolls of cover sheet material 28.1 , 28.2 in the downstream direction. In doing so, the dancer assembly 60 is configured to limit or prevent lateral wandering of the two cover layers 30.1 , 30.2 as they are layered above and below the stack 22 in the laminating assembly 16. The dancer assembly 60 therefore includes a top movable dancer 61 .1 mounted on the frame 45 downstream of the top cover sheet material supply support 26.1 above the feed path 25, and a bottom movable dancer 61 .2 mounted on the frame 45 downstream of the bottom cover sheet material supply support 26.2 below the feed path 25. The movable dancers 61 .1 , 61 .2 may be pivotably coupled to the frame 45 and configured to pivot in response to a pulling tension on the cover layers 30.1 , 30.2. Thus, the movable dancers 61 .1 , 61 .2 are interposed in a respective path of the two cover layers 30.1 , 30.2 between the respective cover sheet material supply supports 26.1 , 26.2 and the conveyor assembly 62 of the laminating assembly 16.

[0071] An exemplary bottom movable dancer 61 .2 is depicted in FIG. 10 as representative of the top and bottom movable dancers 61 .1 , 61 .2 (FIG. 9). The top and bottom movable dancers 61 .1 , 61 .2 may include two rollers 78 and a guide member 70 attached to the dancer 61 .2 via a fixed mounting bracket 71 . Having two rollers 78 in each of the top and bottom movable dancer 61 .1 , 61 .2 allows for a higher volume of cover layer 30.1 , 30.2 intake into the laminating assembly 16 than would occur if the top or bottom movable dancers 61 .1 , 61 .2 had only a single roller 78. The top and bottom movable dancers 61 .1 , 61 .2 may include a pneumatic cylinder to dampen the impact of pulling on the web portions 63.1 , 63.2 (FIG. 9) by adjusting the pressure supplied to the pneumatic cylinder. This control of tension in the web portions 63.1 , 63.2 (FIG. 9) provides consistent lamination of the stack 22 between the two cover layers 30.1 , 30.2 and can be adjusted based on the height of the stack 22, the density of the stack 22, or other parameters.

[0072] The respective guide member 70 of the movable dancers 61 .1 , 61 .2 is coupled, such as rotatably coupled, to at least one tension arm 73 that is coupled, such as pivotably couped, to the frame 45. As shown, the guide member 70 extends between opposed tension arms 73. The movable dancers 61 .1 , 61 .2 may also include a position sensor 113, such as a rotary encoder or potentiometer, to detect a position of one or both of the tension arm 73 and the guide member 70. Thus, the position sensor or rotary encoder may be mounted to the frame 45 adjacent the tension arm 73. Particularly, the position sensor or rotary encoder may measure the angular position of one or both of the tension arm 73 and the guide member 70 of the movable dancers 61 .1 , 61 .2 relative to a default detection area of the movable dancers 61 .1 , 61 .2 as the movable dancers 61 .1 , 61 .2 pivot in opposite directions in response to tension in the cover layers 30.1 , 30.2.

[0073] As shown in FIGS. 1 1 and 12, a motor 112, such as a DC motor, may be connected to a spindle shaft 114 of each cover sheet material supply supports

26.1 . 26.2. The motor 112 may be configured to run in a direction opposite to that in which the spindle shaft 1 14 unwinds the respective rolls of liner cover sheet material

28.1 . 28.2, adding rotational resistance to the spindle shaft 114 and thus increasing the tension in the web portions 63.1 , 63.2. The voltage to the motor 1 12 may be varied by input from the position sensor 1 13 attached to a dancer arm 73 (FIG. 10). The voltage may vary automatically to keep the dancer arm 73 centered in its travel range. Alternatively or additionally, a position sensor may be used to vary the voltage of the motor 112 based on the diameter of the respective rolls of liner cover sheet material 28.1 , 28.2.

[0074] Turning specifically to FIGS. 13 and 14, the conveyor assembly 62 of the laminating assembly 16 includes a pair of top conveyors 81 .1 and a pair of bottom conveyors 81 .2. The pair of top conveyors 81 .1 and the pair of bottom conveyors 81 .2 may be mounted to the frame 45. Specifically, the pair of top conveyors 81 .1 may be mounted to the frame 45 above the feed path 25, and the pair of bottom conveyors 81 .2 may be mounted to the frame 45 below the feed path 25. At least the pair of top conveyors 81 .1 may be mounted to the frame 45 in a way that allows the pair of top conveyors 81 .1 to move upward and downward relative to the pair of bottom conveyors 81 .2 to accommodate different thicknesses of the stack 22, while still using its weight to compress and grip the cover layers 30.1 , 30.2. That is, a gap w1 between the pair of top conveyors 81 .1 and the pair of bottom conveyors 81 .2 may be variable to match or be less than a thickness of the stack 22 travelling therethrough. A compression load can be changed to control the amount of grip and prevent excessive compression that might pierce the layers and reduce thermal or cushioning effectiveness of the resulting stacked liner 12. As shown in FIG. 13, a pneumatic cylinder 90 may be used to control the gap w1 between the pair of top conveyors 81 .1 and the pair of bottom conveyors 81 .2 and the compression load applied therebetween.

[0075] The pair of top conveyors 81 .1 each have a top drive belt 83.1 and the pair of bottom conveyors 81 .2 each have a bottom drive belt 83.2. The respective top and bottom drive belts 83.1 , 83.2 are configured to fictionally engage respective upper and lower surfaces of the cover layers 30.1 , 30.2 to drive the two cover layers 30.1 , 30.2 with the stack 22 therebetween through the conveyor assembly 62 of the laminating assembly 16. The respective top and bottom drive belts 83.1 , 83.2 may be driven in any suitable manner. For example, in the illustrative example, the pair of top conveyors 81 .1 include a top series of rollers 85.1 that, in side elevational view, drive the respective top drive belts 83.1 counterclockwise to feed the materials along the feed path 25. Similarly, the pair of bottom conveyors 81 .2 include a bottom series of rollers 85.2 that, in side elevational view, drive the respective bottom drive belts 83.2 clockwise to feed the materials along the feed path 25. A motor (not shown), such as a servo motor, may be coupled to the respective rollers 85.1 , 85.2 to drive the rollers 85.1 , 85.2.

[0076] As depicted in FIG. 14, the laminating assembly 16 may include a lateral sealing assembly 87 configured to seal lateral edges of the two cover layers

30.1 . 30.2 beyond the lateral edges of the stack 22 therebetween. Specifically, the lateral sealing assembly 87 may include band sealers or heat sealers 84 on the bottom pair of conveyors 81 .2 positioned adjacent each of the bottom drive belts 83.2. The band sealers or heat sealers 84 are positioned so that they contact respective lateral edges of the cover layers 30.1 , 30.2 as they travel through the conveyor assembly 62. A band incorporated in each of the band sealers or heat sealers 84 may be configured to proceed at the same speed as the drive belts 83.1 ,

83.2 to ensure that the speed of the band sealers or heat sealers 84 corresponds to, relates to, or matches the speed of the drive belts 83.1 , 83.2. The corresponding, relation, or matching of the speeds of the band sealers or heat sealers 84 and the drive belts 83.1 , 83.2 may be accomplished by using the same servo motor to drive both the band sealers and drive belts 83.1 , 83.2.

[0077] As shown in FIG. 15, the lateral sealing assembly 87 may also include shoes 88 on the top pair of conveyors 81 .1 that are configured to apply a downward force on the lateral edges of the cover layers 30.1 , 30.2, against the band sealers or heat sealers 84. The shoes 88 may be mounted to pressure cylinders to vary the downward force of the shoes 88 as required by the particular application. In one embodiment, the lateral edges of the cover layers 30.1 , 30.2 include a heat- activated adhesive, and the heat and compression applied to the lateral edges by the heat sealers 84 and the shoes 88 seals the lateral edges together. In another embodiment, another type of adhesive may be applied to the lateral edges, and the compression applied to the lateral edges may seal the lateral edges together.

[0078] Referring next to FIGS. 16 and 17, an end sealing and cutting assembly 38 is shown. The end sealing and cutting assembly 38 may be mounted to the frame 45 adjacent the laminating assembly 16, or may otherwise be provided further downstream of the laminating assembly 16 upstream of an exit conveyor 42. The end sealing and cutting assembly 38 may be actuated via a pneumatic cylinder and may be configured to coordinate with the operation of the laminating assembly 16. For example, the laminating assembly 16 may be stopped or temporarily paused as the end sealing and cutting assembly 38 seals and cuts an upstream/trailing end of the stack 22 and two cover layers 30.1 , 30.2 to form the discrete stacked liner 12. Alternatively or additionally, the end sealing and cutting assembly 38 may be placed on a linear slide unit that is motor controlled to match the speed of the belts 83.1 , 83.2 of the laminating assembly 16. This would allow the sealing and cutting assembly 38 to match the speed of the belts 83.1 , 83.2 and seal and cut the cover layers 30.1 , 30.2 without stopping or pausing operation of the laminating assembly 16.

[0079] The end sealing and cutting assembly 38 includes a top sealing member 92 and a bottom sealing member 94. The bottom sealing member 94 includes two impulse sealing bars 96 separated by a small gap 98. The top sealing member 92 includes a blade 100 and two seal bar backers 102. The blade 100 can be actuated independently from the impulse sealing bars 96, such that the sealing operation and the cutting operation of the end sealing and cutting assembly 38 can be done simultaneously, in series, or separately depending on the application. The blade 110 may be actuated by its respective cut cylinder 117. The bottom sealing member 94 may be actuated by a sealing member cylinder 11 1. The top sealing member 92 may be moved by timing belts. Once the top sealing member 92 and the bottom sealing member 94 are each in contact with the laminated stack 22, impulse heaters in the bottom sealing member 94 are turned on to heat the ends of the top and bottom liner cover sheet material 30.1 , 30.2 and the blade 100 is used to cut the material, if needed. The top sealing member 92 and the bottom sealing member 94 may contact each other without actuating the blade, so that the material may be sealed and creased without cutting. [0080] With reference to FIG. 18, the apparatus 10 may further include an exit conveyor 42 downstream of the sealing and cutting assembly 38. The exit conveyor 42 includes an exit conveyor belt 104 aligned with the flow path 25 along which the stacked liner 12 is conveyed as it exits the laminating assembly 16 and after being sealed and cut by the sealing and cutting assembly 38. An exit conveyor motor 1 16, such as a servo motor, may be coupled to respective exit conveyor rollers 1 18 to drive the exit conveyor rollers 1 18. The exit conveyor belt 104 is configured to convey the stacked liner 12 further in the downstream direction to be accessed by an operator and may be driven, for example, with a DC motor. The exit conveyor belt 104 may be width adjustable, for example, to accommodate various widths of stacked liners 12. The exit conveyor 42 may additionally include a cutting guard 105 (shown in FIG. 4) covering or otherwise downstream of the sealing and cutting assembly 38 to shield the sealing and cutting assembly 38 and prevent an operator from accidentally accessing the sealing and cutting assembly 38 during operation. [0081] The exit conveyor 42 may also include a creasing assembly 106 for creasing the stacked liner 12 at predetermined locations along the downstream direction 18 to allow for easier bending or folding when inserting the stacked liner 12 into a box or other container. The creasing assembly 106 may include two creasing units mounted on adjustable rails mounted to the frame 45. The two creasing units may be positioned between a minimum of approximately 5 inches (12.7 cm) and a maximum of approximately 51 inches (129.5 cm) from each other. Guided cylinders may actuate a creasing blade to apply a downward force on the stacked liner 12 at the predetermined locations to crease the liners, for example, where the liners are being end-sealed and cut.

[0082] The apparatus 10, therefore, allows operator to form a stacked liner 12 having cushioning, wrapping, and thermal insulation properties tailored to any specific application for optimal performance. That is, an operator can variably select any number and combination of layers of dunnage pads and or wadding pads to form a stack 22 for lamination between two cover layer 30.1 , 30.2. This flexibility allows for a resultant stacked liner 12 that is customized for thickness, thermal performance, and cost, and that can be efficiently folded to fit inside and to line the walls of a shipping container.

[0083] An exemplary method of making an insulated stacked dunnage liner, such as the stacked liner 12 described above, may be performed using the apparatus 10 described fully above. That is, the method includes a step of supplying a stack of two or more dunnage pads and/or wadding pads. The method then includes a step of feeding the stack in a downstream direction. The method also includes a step of feeding two layers of liner cover sheet material in the downstream direction. Then, the method includes a step of laminating the stack in between the two layers of liner cover sheet material to form an insulated stacked dunnage liner. [0084] The step of laminating the stack between the two layers of liner cover sheet material may include sealing lateral edges of the two layers of cover sheet material together beyond lateral edges of the stack, to seal the stack therebetween. This step may be accomplished with the band sealers and/or heat sealers, described above.

[0085] The method may further include a step of sealing and cutting an upstream/trailing end of the stack along a direction perpendicular to the downstream direction to form a discrete insulated stacked dunnage liner. For example, this step may be accomplished with the sealing and cutting assembly 38, described above. The method may then further include a step of conveying the insulated stacked dunnage liner, after the step of cutting, in the downstream direction with, for example, the exit conveyor assembly 42 described above. The method may also further include a step of creasing the insulated stacked dunnage liner with, for example, the creasing assembly 106 described above, to allow for easier bending or folding when inserting the insulated dunnage pad into a box or other container. Alternatively or additionally, the insulated stacked dunnage liner may be creased by actuating the sealing and cutting assembly 38 without actuating the blade 100. [0086] All features disclosed herein, including the claims, abstract, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed herein, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise.

[0087] Although the invention defined by the following claims has been shown and described with respect to a certain embodiment, equivalent alternations and modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.

Claims

Claims We claim:

1 . An insulated stacked dunnage liner-making apparatus comprising: a supply assembly configured to receive a stack of two or more dunnage pads and convey the stack in a downstream direction; and a laminating assembly downstream of the supply assembly, the laminating assembly including two cover sheet material supply supports, each configured to support a respective roll of liner cover sheet material, wherein the laminating assembly is configured to: feed the stack in the downstream direction; feed two layers of liner cover sheet material in the downstream direction from the respective rolls of liner cover sheet material supported on each of the two cover sheet material supply supports; and laminate the stack in between the two layers of liner cover sheet material to form an insulated stacked dunnage liner.

2. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 , wherein the two cover sheet material supply supports include: a top cover sheet material supply support mounted above the supply assembly and configured to support a roll of top liner cover sheet material; and a bottom cover sheet material supply support mounted below the supply assembly and configured to support a roll of bottom liner cover sheet material.

3. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-2, wherein the stack of two or more dunnage pads includes at least one insulated dunnage pad having at least one layer of expandable slit sheet material in an expanded state.

4. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-3, wherein the stack of two or more dunnage pads includes at least one wadding pad.

5. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-4, wherein the laminating assembly includes a conveyor assembly having a pair of top conveyors and a pair of bottom conveyors.

6. The insulated stacked dunnage liner-making apparatus as claimed in claim 5, wherein each of the pair of top conveyors include a top drive belt and each of the pair of bottom conveyors include a bottom drive belt.

7. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-6 , wherein the laminating assembly further includes a lateral sealing assembly configured to seal lateral edges of the two layers of cover sheet material beyond lateral edges of the stack therebetween.

8. The insulated stacked dunnage liner as claimed in claim 7, wherein the lateral sealing assembly includes band sealers and corresponding shoes configured to apply a downward force on the lateral edges of the two layers of liner cover sheet material against the band sealers.

9. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-8, wherein the laminating assembly further includes a dancer assembly configured to control tension applied to each of the two layers of liner cover sheet material.

10. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-9, further comprising a sealing and cutting assembly downstream of the laminating assembly and configured to seal and cut a trailing end of the two layers of liner cover sheet material along a direction perpendicular to the downstream direction.

11 . The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-10, further comprising a creasing assembly configured to crease the insulated stacked dunnage liner in one or more predetermined locations along the direction perpendicular to the downstream direction.

12. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-11 , further comprising an exit conveyor assembly configured to convey the insulated stacked dunnage liner further in the downstream direction for access by an operator.

13. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-12, further comprising a controller configured to control an operation of the insulated stacked dunnage liner-making apparatus.

14. The insulated stacked dunnage liner-making apparatus as claimed in claim 1 or any of claims 1-13, wherein the supply assembly includes a stacking conveyor configured to receive the stack of two or more dunnage pads and convey the stack in the downstream direction.

15. The insulated stacked dunnage liner-making apparatus as claimed in claim 14, wherein the supply assembly further includes a spacing conveyor downstream of the stacking conveyor, the spacing conveyor configured to maintain a gap between the stack and a succeeding stack of two or more dunnage pads in the supply assembly.

16. A method of making an insulated stacked dunnage liner comprising the steps of: supplying a stack of two or more dunnage pads; feeding the stack in a downstream direction; feeding two layers of liner cover sheet material in the downstream direction; and laminating the stack in between the two layers of liner cover sheet material to form an insulated stacked dunnage liner.

17. The method as claimed in claim 16, wherein the step of laminating the stack in between the two layers of liner cover sheet material includes sealing lateral edges of the two layers of cover sheet material together beyond lateral edges of the stack to seal the stack therebetween.

18. The method as claimed in claim 16 or any of claims 16-17, further comprising a step of sealing and cutting a trailing end of the two layers of liner cover sheet material along a direction perpendicular to the downstream direction.

19. The method as claimed in claim 16 or any of claims 16-18, further comprising a step of conveying the insulated stacked dunnage liner in the downstream direction, after the step of cutting.

20. The method as claimed in claim 16 or any of claims 16-19, further comprising a step of creasing the insulated stacked dunnage liner at one or more predetermined locations along a direction perpendicular to the downstream direction.