U.S. patent application number 13/470444 was filed with the patent office on 2012-09-06 for dunnage conversion machine and method.
This patent application is currently assigned to Ranpak Corp.. Invention is credited to Robert C. Cheich, David V. Murphy, Raymond Paulus Hubertus Nolle, Maurice Jozef Paulus Anthonius Savelberg, Steven M. Toneff, Pedro Erik Willem Winkens.
Application Number | 20120225765 13/470444 |
Document ID | / |
Family ID | 40336735 |
Filed Date | 2012-09-06 |
United States Patent
Application |
20120225765 |
Kind Code |
A1 |
Cheich; Robert C. ; et
al. |
September 6, 2012 |
DUNNAGE CONVERSION MACHINE AND METHOD
Abstract
A dunnage conversion machine (36) converts a sheet stock
material into a dunnage product that is relatively thicker and less
dense than the stock material, but is relatively thin and
sufficiently flexible to function as a protective wrap. The
conversion machine includes a feed mechanism (40) that advances a
sheet stock material therethrough and a connecting mechanism (42)
downstream of the feed mechanism. The connecting mechanism retards
the passage of the sheet stock material therethrough by feeding the
stock material therethrough at a slower rate than the feed
mechanism feeds the stock material to the connecting mechanism.
This causes the stock material to randomly crumple in a
longitudinal space between the feed mechanism and the connecting
mechanism. The connecting mechanism connects multiple overlapping
layers of sheet stock material together as they pass therethrough,
including connecting at least one crumpled sheet to one side of one
other sheet.
Inventors: |
Cheich; Robert C.;
(Independence, OH) ; Murphy; David V.;
(Painesville, OH) ; Toneff; Steven M.;
(Painesville, OH) ; Savelberg; Maurice Jozef Paulus
Anthonius; (Partij, NL) ; Nolle; Raymond Paulus
Hubertus; (Heerlen, NL) ; Winkens; Pedro Erik
Willem; (Vaals, NL) |
Assignee: |
Ranpak Corp.
Concord Township
OH
|
Family ID: |
40336735 |
Appl. No.: |
13/470444 |
Filed: |
May 14, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13094165 |
Apr 26, 2011 |
8177697 |
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13470444 |
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12236948 |
Sep 24, 2008 |
7955245 |
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13094165 |
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60974532 |
Sep 24, 2007 |
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61035701 |
Mar 11, 2008 |
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61076365 |
Jun 27, 2008 |
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Current U.S.
Class: |
493/464 |
Current CPC
Class: |
B31D 2205/007 20130101;
Y10S 493/967 20130101; B65D 81/03 20130101; B31D 2205/0035
20130101; Y10T 428/24628 20150115; Y10T 428/2495 20150115; B31D
2205/0082 20130101; B32B 3/28 20130101; Y10T 428/249922 20150401;
B31D 2205/0088 20130101; A61F 9/0017 20130101; B31D 5/0047
20130101; B31D 2205/0047 20130101; B31D 2205/0058 20130101; B31D
5/0052 20130101; B31D 2205/0064 20130101 |
Class at
Publication: |
493/464 |
International
Class: |
B31B 1/00 20060101
B31B001/00 |
Claims
1-30. (canceled)
31. A dunnage conversion machine, comprising a shelf for supporting
a supply of stock material; a conversion assembly for converting a
stock material into a dunnage product; and a stand that supports
the conversion assembly and the shelf; where the shelf is linearly
movable between an operating position adjacent the conversion
assembly and a loading position spaced from the operating position
for loading stock material without moving the conversion
assembly.
32. A machine as set forth in claim 31, wherein the conversion
assembly is capable of converting a stock material into a dunnage
product as the stock material moves through the conversion assembly
in an upstream-to-downstream direction, and the loading position of
the shelf is downstream of the operating position.
33. A machine as set forth in claim 31, wherein the shelf is
mounted to the stand by a pair of parallel, spaced apart,
telescoping support and guide members.
34. A machine as set forth in claim 31, wherein the stand supports
the conversion assembly above the shelf.
35. A machine as set forth in claim 31, wherein in the operating
position the shelf is under the conversion assembly.
36. A machine as set forth in claim 31, comprising a supply of
stock material supportable on the shelf, wherein the stock material
includes one or more stacks of fan-folded sheet stock material.
37. A machine as set forth in claim 31, wherein the shelf defines a
horizontal, substantially flat and continuous surface for
supporting a supply of stock material.
38. A method of loading a dunnage conversion machine comprising the
steps of: (a) providing the dunnage conversion machine of claim 31;
(b) linearly moving the shelf from the operating position to the
loading position without moving the conversion assembly; (c)
loading a supply of stock material onto the shelf; and (d)
returning the shelf to the operating position.
39. A method as set forth in claim 38, comprising the step of
splicing a new supply of stock material to an almost-spent supply
of stock material before the step of returning the shelf to the
operating position.
40-53. (canceled)
Description
[0001] We claim the benefit of U.S. Provisional Patent Application
Nos. 60/974,532, filed 24 Sep. 2007; 61/035,701, filed 11 Mar.
2008; and 61/076,365, filed 27 Jun. 2008, each of which is
incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention is related to dunnage conversion
machines, and more particularly to a stock supply assembly and an
output chute for a dunnage conversion machine, and a corresponding
method, as well as a dunnage conversion machine and method for
making a wrappable dunnage product from a sheet stock material.
BACKGROUND
[0003] Dunnage conversion machines convert a stock material into a
dunnage product that can be used to pack articles and thus minimize
or prevent damage during shipment. The dunnage conversion machines,
also referred to as dunnage converters, include a conversion
assembly that converts a stock material into a relatively lower
density dunnage product as the stock material moves through the
conversion assembly from an upstream end toward an outlet at a
downstream end.
[0004] At the upstream end of the converter, a supply of stock
material is fed into the conversion assembly. The stock material
typically is stored adjacent the conversion assembly, which
consumes the stock material as it produces strips of dunnage from
which dunnage products are severed. When the converter is deployed
underneath a table or other work surface, keeping the stock
material under the table keeps it out of the way, but makes
replenishing the stock material difficult.
[0005] At the downstream end, dunnage conversion machines often
include an output chute secured to the housing or frame of the
converter to guide dunnage products away from the outlet. The
output chute supports and guides the dunnage products and can
prevent the exiting dunnage products from causing jams in the
conversion assembly. A typical dunnage product has a length of
about twenty to about seventy centimeters. If a dunnage product
does not exit the output chute on its own, a subsequent dunnage
product typically will push it out of the chute.
[0006] A wrappable dunnage product may be advantageous for
layering, including placement between relatively flat items such as
plates, and/or for individually wrapping articles such as fragile
ornaments, glass lamps, or the wooden legs on fine furniture, to
minimize or prevent damage during shipment. Not all dunnage is
suitable for use as a wrapping product, however. Some dunnage
products in pad form, for example, can be too narrow and/or stiff
to be used effectively as a protective wrapping product.
[0007] Existing wrappable dunnage products include foldable
cardboard and plastic bubble wrap. Unfortunately, both take up a
lot space for storage until ready to use. Cardboard typically has a
sinusoidal, regularly undulating ply glued to one or more generally
planar plies. Some cardboard is made using pleating rollers that
extend across the width of a sheet to form the regular sinusoidal
shape as the sheet passes between the rollers. These pleating
rollers are very expensive to make. Cardboard also is difficult to
produce on demand since the glue holding the layers together has to
dry before use. Therefore, on-demand conversion of a stock material
into a cardboard-like wrapping dunnage product probably is not
practical.
[0008] Unlike cardboard, plastic bubble wrap can be made on demand,
but the process is very slow (generally about nine meters per
minute, compared to about twenty meters per minute for some
converters that produce paper dunnage) and its speed is limited by
the nature in which bubble wrap is made. Additionally, plastic is
increasingly expensive, as well as increasingly being seen as bad
for the environment.
SUMMARY
[0009] We have developed a wrappable dunnage product that can be
produced relatively quickly on demand from a sheet stock material
for immediate use. An exemplary stock material is kraft paper,
which is biodegradable, recyclable, and composed of a renewable
resource.
[0010] More specifically, the present invention provides a
wrappable dunnage product, a dunnage converter for converting a
sheet stock material into a wrappable dunnage product, and a
corresponding method for producing a wrappable dunnage product. In
particular, the present invention provides a multi-ply dunnage
product that has sufficient flexibility and loft to be used as a
protective wrap. At least one layer of the dunnage product includes
a randomly crumpled web or sheet. Randomly crumpling at least one
sheet provides cushioning properties to the dunnage wrap, while
lines of connection where the multiple overlaid sheets or plies are
held together mechanically help the dunnage wrap retain its
structure. These lines of connection also can provide convenient
fold lines.
[0011] Additionally, a dunnage converter and method provided by the
present invention can be employed to produce a wrappable dunnage
product without employing pleating rollers. Although pleating
rollers can be used to form regular folds in the stock material,
they are relatively expensive and tend to provide different
protective properties because the fold lines formed in the stock
material are consistently parallel to each other.
[0012] An exemplary dunnage conversion machine for converting a
sheet stock material into a wrapping dunnage product that is
relatively thicker and less dense than the stock material includes
a feed mechanism and a connecting mechanism downstream of the feed
mechanism. The feed mechanism advances at least a first web of
sheet stock material therethrough at a first rate. The connecting
mechanism (a) retards the advancement of the sheet stock material
by passing the sheet stock material therethrough at a second rate
that is less than the first rate, thereby causing the first web to
randomly crumple in a longitudinal space between the feed mechanism
and the connecting mechanism, and (b) connects the crumpled first
web to a second web to maintain the crumpled first web in its
crumpled state. The second web may pass through the feed mechanism
and crumple between the feed mechanism and the connecting
mechanism, or bypass the feed mechanism and join the first web as
an uncrumpled ply.
[0013] An exemplary dunnage product includes multiple plies of
sheet stock material connected together, including at least one
randomly crumpled sheet having an irregular pitch that is connected
to one side of another sheet to maintain the crumpled sheet in its
crumpled state. An exemplary stock material includes paper.
[0014] And an exemplary method for producing a dunnage product
includes the following steps: (i) advancing at least a first web of
sheet stock material through an upstream feed mechanism, (ii)
retarding the passage of the sheet stock material downstream of the
feed mechanism by passing the sheet stock material at a second rate
that is less than the first rate to cause the first web to randomly
crumple, and (iii) connecting multiple layers of sheet stock
material, including connecting the crumpled first web to one side
of a second web of sheet stock material, to hold the crumpled first
web in its crumpled state.
[0015] Another dunnage conversion machine provided by the invention
for converting a sheet stock material into a dunnage product
includes a feed mechanism for advancing a sheet stock material
therethrough at a first rate, and a connecting mechanism downstream
of the feed mechanism that (a) retards the advancement of the sheet
stock material by passing the sheet stock material therethrough at
a second rate that is less than the first rate, thereby causing at
least one sheet to randomly crumple in a longitudinal space between
the feed mechanism and the connecting mechanism, and (b)
mechanically connects multiple sheets of stock material together to
hold the crumpled sheet in its crumpled state.
[0016] Yet another dunnage conversion machine for converting a
sheet stock material into a dunnage product includes a feed
assembly for advancing a sheet stock material therethrough at a
first rate, and a connecting assembly downstream of the feed
assembly that (a) advances the sheet stock material therethrough at
a second rate that is less than the first rate, thereby causing at
least one sheet of stock material to randomly crumple in a
longitudinal space between the feed assembly and the connecting
assembly, and b) mechanically connects multiple sheets together,
including at least one crumpled sheet, to maintain the crumpled
sheet in its crumpled state.
[0017] Another method for producing a dunnage product includes the
steps of (i) advancing a sheet stock material at a first rate, and
(ii) mechanically connecting multiple layers of sheet stock
material together at a second rate that is less than the first rate
to cause at least one sheet of stock material to randomly crumple
within a confined space before being connected to another sheet to
maintain the crumpled sheet in its crumpled state.
[0018] Still another dunnage conversion machine for converting a
sheet stock material into a wrapping dunnage product includes (i)
means for advancing a sheet stock material at a first rate, and
(ii) means for mechanically connecting multiple layers of sheet
stock material together at a second rate that is less than the
first rate to cause at least one sheet of stock material to
randomly crumple within a confined space before being connected to
another sheet to maintain the at least one crumpled sheet in its
crumpled state.
[0019] Other concepts provided by the present invention include:
(i) means for guiding at least one sheet of stock material to a
connecting means at the second rate so that at least one sheet that
is connected to the crumpled sheet is not crumpled; (ii) a guide
for guiding at least one sheet of stock material to the connecting
mechanism and bypassing the feed mechanism to connect the crumpled
sheet to an uncrumpled sheet to form a relatively flat wrapping
dunnage product that retains its shape; (iii) a bunching assembly
upstream of the feed mechanism that inwardly gathers the sheet
stock material to encourage the formation of
longitudinally-extending fold lines in the stock material; (iv) a
separator that cooperates with channel guides to define multiple
channels for the stock material to travel through the feed
mechanism to the connecting mechanism, whereby the channels confine
the stock material as it crumples between the feed mechanism and
the connecting mechanism, and each channel has a different height
to promote different frequencies and amplitudes in the crumpling of
respective webs of sheet stock material, (v) laterally-spaced
forming members that extend into the path of lateral edge portions
of the sheet stock material to urge those lateral edge portions
inward to reinforce the edges of the stock material as those edge
portions pass through the connecting mechanism; (vi) a series of
transversely-extending serpentine guides upstream of the feed
mechanism that define a serpentine path for the sheet stock
material to improve its tracking and maintaining a minimum tension
in the stock material drawn therethrough; (vii) wherein the
aforementioned serpentine guides include three parallel rollers
arranged with the axes generally in a common plane, and at least
one roller is pivotable between an operating position in line with
the other rollers and a loading position spaced from the operating
position to provide a large gap for threading the stock material
therethrough; (viii) where the connecting mechanism includes at
least one pair of gears that intermesh to connect the multiple
layers of stock material, the gears include at least two
laterally-spaced segments on opposing sides of an annular recess
therebetween, and a stripper bar extends through the annular recess
a distance upstream and downstream of the gears to help release the
stock material from the gears; and (ix) wherein the feed mechanism
includes at least one pair of rotating members that feed the stock
material therebetween, and a mechanism for moving at least one of
the rotating members away from the other to facilitate loading a
sheet stock material therebetween.
[0020] We have found that relatively short dunnage products, having
a length of less than about fifteen centimeters, for example, tend
to shingle, twist, or otherwise jam and block passage through the
output chute. And subsequent strips of dunnage add to the jam
rather than pushing preceding dunnage products out of the
chute.
[0021] By moving the output chute out of the way, relatively short
dunnage products can take an alternate route or path and fall
through a gravity chute rather than being fed into the output chute
where they might jam.
[0022] An exemplary dunnage conversion machine provided by the
present invention includes a conversion assembly for converting a
stock material into a dunnage product and dispensing the dunnage
product through an outlet. The conversion assembly is capable of
producing dunnage products of multiple lengths. The conversion
assembly also includes an output chute adjacent the outlet. The
output chute is moveable between a first position where the output
chute is aligned with the outlet so that dunnage products having at
least a predetermined minimum length are dispensed through the
outlet into the output chute, and a second position where the
output chute is not aligned with the outlet so that dunnage
products having a length less than the predetermined minimum length
that are dispensed through the outlet bypass the output chute.
[0023] Another exemplary dunnage conversion machine provided by the
invention includes a conversion assembly for converting a stock
material into a dunnage product and for dispensing the dunnage
product through an outlet. This conversion machine also includes an
output chute adjacent the outlet. The output chute has walls that
define a passage through the output chute. The output chute is
moveable between a first position where the passage is aligned with
the outlet to receive dunnage products, and a second position where
the passage is not aligned with the outlet. The conversion machine
also includes a controller that enables selection of a desired
length of a dunnage product and controls the position of the outlet
chute so that in its first position dunnage products dispensed
through the outlet enter the passage through the output chute, and
in its second position dunnage products dispensed through the
outlet bypass the output chute.
[0024] Another exemplary dunnage conversion machine includes a
conversion assembly for converting a stock material into a dunnage
product as the stock material travels from an upstream end of the
conversion assembly to a downstream end of the conversion assembly.
The conversion assembly also includes a housing that defines an
outlet for dispensing the dunnage product. The conversion machine
also includes an output chute adjacent the outlet. The output chute
has an upstream end that is moveable relative to the outlet between
a first position where the upstream end of the output chute is
aligned with the outlet to receive dunnage products from the
conversion assembly, and a second position where the upstream end
of the output chute is not aligned with the outlet so that dunnage
products from the conversion assembly bypass the output chute.
[0025] Yet another dunnage conversion machine includes a conversion
assembly for converting a stock material into a dunnage product as
the stock material travels from an upstream end of the conversion
assembly to a downstream end of the conversion assembly. The
conversion assembly includes a housing that defines an outlet for
dispensing the dunnage product. The conversion machine also
includes a chute adjacent the outlet. The conversion assembly
dispenses dunnage products through the outlet in a downstream
direction. The chute has a gravity portion that extends in a
direction transverse the downstream direction, and an output chute
portion that is moveable between a first position where the
upstream end of the output chute portion is aligned with the outlet
and a second position where the upstream end of the output chute
portion is spaced from the outlet. In the first position, the
output chute portion closes the gravity portion, and in the second
position the gravity chute portion is open to the outlet.
[0026] An exemplary method of dispensing dunnage products includes
the steps of (a) converting a stock material into a dunnage product
and dispensing the dunnage product through an outlet, (b) if the
dunnage product has at least a predetermined minimum length, moving
an upstream end of an output chute adjacent to and in alignment
with the outlet to receive, support, and guide the dunnage product
as it exists the outlet. If the dunnage product has a length that
is less than the predetermined minimum length, the method includes
the step of moving the upstream end of the output chute relative to
the outlet so that dunnage products exiting the outlet bypass the
output chute.
[0027] To make it easier to re-stock the supply of stock material,
the present invention provides a shelf that slides out for
restocking, away from the conversion assembly, and slides back in
to be out of the way while the dunnage converter is operating.
[0028] An exemplary dunnage conversion machine provided by the
present invention includes a shelf for supporting a supply of stock
material, a conversion assembly for converting a stock material
into a dunnage product, and a stand that supports the conversion
assembly and the shelf. The shelf is linearly movable between an
operating position adjacent the conversion assembly and a loading
position spaced from the operating position for loading stock
material without moving the conversion assembly.
[0029] The foregoing and other features of the invention are
hereinafter fully described and particularly pointed out in the
claims, the following description and annexed drawings setting
forth in detail certain illustrative embodiments of the invention,
these embodiments being indicative, however, of but a few of the
various ways in which the principles of the invention may be
employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic representation of an exemplary dunnage
conversion machine provided in accordance with the present
invention.
[0031] FIG. 2 is a schematic perspective view of operative elements
of an exemplary dunnage conversion machine provided in accordance
with the present invention.
[0032] FIG. 3 is a top view of the dunnage conversion machine shown
in FIG. 2.
[0033] FIG. 4 is a cross-sectional view of the dunnage conversion
machine shown in FIG. 3, looking downstream as seen along lines
4-4.
[0034] FIG. 5 is a cross-sectional side view of the dunnage
conversion machine shown in FIG. 3, as seen along lines 5-5.
[0035] FIG. 6 is a cross-sectional end view of the dunnage
conversion machine shown in FIG. 2, looking upstream as seen along
lines 6-6.
[0036] FIG. 7 is a schematic view of a dunnage product produced by
the dunnage conversion machine shown in FIG. 3.
[0037] FIG. 8 is a schematic representation of another dunnage
conversion machine provided in accordance with the present
invention.
[0038] FIG. 9 is a perspective view of an exemplary dunnage
conversion machine consistent with the schematic representation in
FIG. 8.
[0039] FIG. 10 is a cross-sectional elevation view of a portion of
the dunnage conversion machine of FIG. 9 as seen generally along
lines 10-10 in FIG. 9.
[0040] FIG. 11 is a schematic perspective view of a dunnage product
produced by the dunnage conversion machine of FIG. 9.
[0041] FIG. 12 is a schematic perspective view of a packaging
system including yet another dunnage conversion machine.
[0042] FIG. 13 is a perspective view of the dunnage conversion
machine of FIG. 12 with the left side and top panels of its housing
removed to reveal the internal components.
[0043] FIG. 14 is a top view of the dunnage conversion machine of
FIG. 13, looking in direction 14-14 in FIG. 13.
[0044] FIG. 15 is a cross-sectional side view of the dunnage
conversion machine of FIG. 12, looking in direction 15-15 in FIG.
14.
[0045] FIG. 16 is a perspective view from the side of an exemplary
stock material supply cart for use with a dunnage conversion
machine.
[0046] FIG. 17 is a perspective view from above the stock material
supply cart of FIG. 16.
[0047] FIG. 18 is an enlarged side view of an upstream end of the
dunnage conversion machine of FIG. 15.
[0048] FIG. 19 is an enlarged schematic perspective view of a
portion of a feed assembly of the dunnage conversion machine of
FIG. 13.
[0049] FIG. 20 is a cross-sectional view of FIG. 19 taken along
lines 20-20 and looking in the indicated direction represented by
the corresponding arrows.
[0050] FIG. 21 is a cross-sectional view of FIG. 19 taken along
lines 21-21 and looking in the direction indicated by the
corresponding arrows.
[0051] FIG. 22 is a perspective view of a rear, upper portion of
the dunnage conversion machine of FIG. 12.
[0052] FIG. 23 is an enlarged cross-sectional view of a portion of
a connecting assembly of the dunnage conversion machine of FIG. 13
looking in direction 23-23 of FIG. 14.
[0053] FIG. 24 is an enlarged cross-sectional view of a portion of
the connecting assembly of the dunnage conversion machine of FIG.
13, looking in direction 24-24 of FIG. 15.
[0054] FIG. 25 is a perspective view of a drive chain portion seen
from the right of the dunnage conversion machine of FIG. 13 with
the relevant covers of the housing removed to reveal its
components.
[0055] FIG. 26 is a front elevation view of a downstream portion of
the dunnage conversion machine of FIG. 12 with the housing removed
to reveal a cutting assembly.
[0056] FIG. 27 is an enlarged cross-sectional view of the cutting
assembly of FIG. 26 as seen along lines 26-26.
[0057] FIG. 28 is perspective view of an exemplary dunnage
conversion machine with a sliding shelf in accordance with the
present invention.
[0058] FIG. 29 is a side view of the dunnage conversion machine
shown in FIG. 28 with the shelf in a working position.
[0059] FIG. 30 is a side view of the dunnage conversion machine
shown in FIG. 28 with the shelf in a loading position.
[0060] FIG. 31 is a schematic perspective view of another dunnage
conversion machine provided in accordance with the present
invention.
[0061] FIG. 32 is a schematic illustration of the dunnage
conversion machine of FIG. 31 with an exemplary output chute
provided in accordance with the present invention.
[0062] FIG. 33 is an enlarged cross-sectional elevation view of the
output chute of FIG. 32.
[0063] FIG. 34 is a perspective view of another exemplary output
chute provided in accordance with the present invention, with the
output chute in a first position.
[0064] FIG. 35 is a top view of the output chute of FIG. 34.
[0065] FIG. 36 is an end view of the output chute of FIG. 34.
[0066] FIG. 37 is a side view of the output chute of FIG. 34 in a
second position.
[0067] FIG. 38 is a bottom view of the output chute of FIG. 37.
DETAILED DESCRIPTION
[0068] The present invention provides a dunnage conversion machine
and method for making a wrappable dunnage product from a sheet
stock material, as well as a stock supply assembly and an output
chute for a dunnage conversion machine, and corresponding
methods.
Wrappable Dunnage
[0069] The present invention provides a wrappable dunnage product,
a dunnage converter for converting a sheet stock material into a
wrappable dunnage product, and a corresponding method for producing
a wrappable dunnage product that is relatively thicker and less
dense than the stock material. In particular, the present invention
provides a multi-ply dunnage product that has sufficient
flexibility and loft to be used as a protective layer or wrap. At
least one ply of the dunnage product includes a randomly crumpled
web or sheet. Randomly crumpling at least one sheet provides
cushioning properties to the dunnage wrap. The crumpled sheet or
sheets are held in the crumpled state along lines of mechanical
interconnection with at least one other sheet, where the lines of
connection where the multiple overlaid sheets or plies are held
together can provide convenient fold lines.
[0070] Additionally, the dunnage converter and method provided by
the present invention can be employed to produce a dunnage product
relatively quickly on demand as needed without the expensive
pleating rollers that create regular parallel folds in a sheet
stock material. Moreover, the converter and the stock material take
up much less space than the wrapping dunnage product produced
therefrom.
[0071] Referring now to FIG. 1, an exemplary dunnage conversion
system 10 provided by the invention includes a supply 12 of
multiple webs of sheet stock material and a conversion machine 16
that converts the stock material into a wrapping dunnage product. A
suitable sheet stock material includes paper and/or plastic sheets,
supplied as a roll or a fan-folded stack, for example. An exemplary
sheet stock material for use in the conversion machine 16 includes
either a single ply or a multi-ply kraft paper provided either in
roll form or as a series of connected rectangular pages in a
fan-folded stack. Multiple rolls or stacks may be used to provide
the multiple sheets or webs of stock material for conversion to the
multi-ply dunnage product.
[0072] The dunnage conversion machine 16 includes a feed mechanism
20 for advancing at least one first sheet or web of stock material
therethrough, and a connecting mechanism 22 for connecting multiple
overlapping sheets together downstream of the feed mechanism 20. By
passing the stock material at a slower rate than the feed mechanism
20 advances the stock material thereto, the connecting mechanism 22
retards the passage of the sheet stock material therethrough, which
causes the stock material to randomly longitudinally crumple or
fold in a confined space extending longitudinally between the feed
mechanism 20 and the connecting mechanism 22.
[0073] The connecting mechanism 22 connects multiple overlying
sheets of the stock material, including connecting at least one
crumpled first sheet to one side of another or second sheet, to
form a crumpled strip of dunnage 23. The second sheet may be a
crumpled sheet that also passes through the feed mechanism 20 or an
uncrumpled sheet that bypasses the feed mechanism 20. The
conversion machine also may include a bunching assembly 24 to
inwardly gather the sheet stock material upstream of the feed
mechanism 20 and/or a cutting mechanism 26 downstream of the
connecting mechanism 22 to sever discrete dunnage products 28 from
the strip 23 of connected sheets.
[0074] In some situations the cutting mechanism 26 can be omitted
altogether, such as when discrete lengths of sheet stock material
are supplied to the feed mechanism 20 and the connecting mechanism
22. Another alternative is to employ a sheet stock material that is
perforated across its width so that a length of wrapping dunnage
can be torn from the strip of dunnage. The perforations can be
formed in the stock material before being supplied to the
conversion machine 16 or formed as part of the conversion process.
Additionally, the conversion machine 16 can automatically separate
a desired length of wrapping dunnage from a strip of dunnage made
of perforated stock material. This can be accomplished by stopping
the feed mechanism 20 to hold an upstream portion of the sheet
stock material while the connecting mechanism 22 continues to feed
the stock material therethrough. As a result, the stock material
will automatically separate at a line of perforations located
between the feed mechanism 20 and the connecting mechanism 22.
[0075] Referring now to FIGS. 2-5, further details of an exemplary
conversion machine 36 are shown. Following a path of the stock
material as it moves downstream through each component of the
conversion machine 36, the conversion machine 36 includes a
bunching assembly 38, a feed assembly or mechanism 40, a connecting
assembly or mechanism 42, and a cutting assembly or mechanism 44.
The feed mechanism 40 draws one or more first sheets of stock
material from a supply 46 (FIG. 5), over one or more bars or
rollers 47, 48, and 49 that guide each sheet through or around the
bunching assembly 38.
[0076] The bunching assembly 38 laterally inwardly gathers the one
or more sheets passing therethrough. This inward gathering can
prevent or minimize tearing of the stock material and promote loft
as the stock material is fed into the feed mechanism 40. The
illustrated bunching assembly 38 includes lateral guides 50 that
extend transverse the thickness of the stock material, generally
upright in the illustrated orientation. The lateral guides 50 are
laterally spaced on opposing sides of the path of the sheet stock
material, for example at a distance that is less than the width of
the sheet, to reduce the width of the stock material.
[0077] The illustrated bunching assembly 38 also includes upper and
lower guide members 52 and 54, which in the illustrated embodiment
include guide wheels 56 that bear against the stock material. The
upper and lower guide members 52 and 54 are laterally-spaced and
transversely offset from one another. The guide members 52 and 54
extend into the path of the sheet stock material alternately from
above and from below at locations spaced across the width of the
path, causing the stock material to transversely undulate
therebetween (see FIG. 4). The bunching assembly 38 thus gathers or
bunches a greater quantity of sheet stock material toward the
center of the path, which may lead to lateral crumpling as the
sheet or sheets subsequently pass through the feed mechanism 40.
Lateral crumpling can create fold lines approximately parallel to a
longitudinal dimension of the stock material (generally parallel to
the path of the stock material) and/or an interruption of the
lateral fold lines created by longitudinal crumpling between the
feed mechanism 40 and the connecting mechanism 42 as described
below. The lateral and longitudinal crumpling of the sheet stock
material is believed to enhance the cushioning properties of the
dunnage product. The spacing between the lateral guides 50 also can
be adjustable to accommodate different widths of the stock material
or to vary the amount of gathering or bunching. The bunching
assembly 38 can be omitted or placed between the feed mechanism 40
and the connecting mechanism 42 in alternative embodiments.
[0078] From the bunching assembly 38, the inwardly-drawn stock
material passes to the feed mechanism 40. The illustrated feed
mechanism 40 includes at least two rotating feed members 60 and 61
for advancing the sheet stock material therebetween. The feed
members 60 and 61 have a surface that provides sufficient friction
to grip the stock material, and may be knurled or have a rubber or
other high-friction surface, for example, to provide the desired
grip on the stock material. The feed mechanism 40 can include one
pair of rotating members, a single rotating member on one side of
the sheet stock material and multiple rotating members on the other
side of the stock material, or as shown, multiple laterally-spaced
pairs of rotating members 60 and 61 for advancing the sheet stock
material therethrough. The opposing rotating members 60 and 61 in
each pair preferably, but not necessarily, are biased against one
another to maintain a grip on the sheet stock material passing
therebetween. The illustrated rotating members are mounted on a
common shaft, however, each pair of the rotating members 60 and 61
may be independently biased toward each other, similar to the
arrangement described with respect to the connecting mechanism 36
in the following paragraphs.
[0079] The rotating members 60 and 61 additionally can have
portions that allow the stock material to periodically slip
relative to the rotating members 60 and 61. This relative slip can
be accomplished, for example, by providing flat portions 62 on the
illustrated rotating members 60 and 61. If these flat portions 62
are circumferentially spaced at laterally spaced locations across
the width of the stock material, a lateral shifting or twisting
motion can be imparted to the stock material to cause differential
lateral crumpling between the rotating members 60 and 61 and a
longitudinal space between the feed mechanism 40 and the connecting
mechanism 42.
[0080] The connecting mechanism 42 receives the stock material from
the feed mechanism 40, and optionally also may receive one or more
sheets that bypass the feed mechanism 40 to provide an uncrumpled
backing and/or cover sheet or sheets. The illustrated connecting
mechanism 42 includes at least two rotating gear members 70 and 71
having interlaced teeth for deforming the sheet stock material
passing therebetween, thereby mechanically interlocking multiple
layers and multiple overlapping sheets along lines of connection to
hold them together as a connected strip of dunnage. This mechanical
connection is distinguished from a chemical or adhesive bond
between the layers. The gear members 70 and 71 flatten, crease,
fold, and/or punch the stock material as it passes therebetween.
Although the connecting mechanism 42 includes at least two rotating
gear members 70 and 71 between which the stock material is fed,
more gear members may be employed in various configurations, as
described with respect to the feed members 60 and 61. Thus the gear
members 70 and 71 may include a single gear stretching across the
width of the stock material opposed by another gear, or one or more
gears opposing the single gear at laterally-spaced positions, or
the illustrated plurality of laterally-spaced pairs of opposed
gears 70 and 71.
[0081] The rotating gear members 70 and 71 are driven at a rate
that is less than the rate that the feed mechanism 40 advances the
sheet stock material thereto. In an exemplary embodiment each pair
of connecting gears 70 and 71 includes a biasing member 74 that
biases one gear 70 toward an opposing gear 71 and thereby provides
an adjustable pinch pressure between each pair of gears.
Accordingly, if more tension is needed at a particular location,
for example toward an outer edge of the sheet stock material,
selected gears may have their pinch pressure adjusted to effect the
desired quality or character of the connection between the multiple
sheets passing therebetween.
[0082] Thus in the illustrated embodiment the gear members 71 on
one side of the path are supported by pivot shafts 75 pivotally
connected to a corresponding axle 76 of the feed mechanism 40. Each
gear member 71 is biased toward the opposing gear member 70 by a
biasing device 74 that includes a spring 77. The spring 77 is
interposed between a fixed frame member 78 and a yoke 79 connected
to the gear member 71 and the pivot shafts 75. A bolt 81 axially
aligned with and on one side of the spring 77 is threadably mounted
to the frame member 78 to allow for adjustment of the biasing force
applied by the spring 77. Because each of the gear members 77 is
independently supported and biased toward the opposing gear member
70, differential pinch pressure may be applied at locations spaced
across the width of the stock material. The present invention is
not limited to the illustrated structure, however, and equivalent
biasing devices may be employed to provide independent
adjustability at different locations as the stock material passes
through the connecting mechanism 42.
[0083] Guide chute or tunnel elements 80 constrain the movement of
the stock material passing between the feed mechanism 40 and the
connecting mechanism 42 to cause the stock material driven
therebetween to randomly crumple within the restricted longitudinal
space defined by the walls of the tunnel 80, the feed mechanism 40
and the connecting mechanism 42. Longitudinal crumpling creates
fold lines extending approximately transverse the longitudinal
dimension of the stock material, which generally is perpendicular
to the path of the stock material through the machine 36. When
longitudinal crumpling is combined with crumpling action caused by
the inward bunching of the bunching assembly 38 and any lateral
twisting or shifting caused by the feed mechanism 40, the sheet
stock material is randomly crumpled, creating fold lines with
random lengths and orientations, and an irregular pitch between the
folds.
[0084] To connect one or more uncrumpled sheets of stock material
to the crumpled sheet or sheets, the dunnage converter 36 can
provide a bypass path for an uncrumpled sheet or sheets to bypass
the feed mechanism 40 and join with the crumpled sheet or sheets at
the connecting mechanism 42. The connecting mechanism 42 then
connects the uncrumpled sheet or sheets to the crumpled sheet or
sheets. To that end a bypass guide member, such as a guide bar or
roller 49, may be provided to guide the uncrumpled sheet or sheets
around the bunching assembly 38 and/or the feed mechanism 40 to the
connecting mechanism 42. A corresponding guide bar or roller can be
provided on an opposing side of the feed mechanism 40 to direct one
or more additional uncrumpled sheets around the feed mechanism 40
to be secured to an opposing side of the one or more crumpled
sheets by the connecting mechanism 42.
[0085] To obtain the desired length of dunnage products, the sheet
stock material may be perforated across its width so that lengths
of the finished products can be torn off as desired for use in
wrapping an article or for layering inside a container. The
perforations can be formed prior to the stock material being
supplied to the conversion machine or formed as part of the
conversion process, as noted above. A rotating perforating wheel,
rotating in the direction of the stock material, can operate
without stopping the conversion process. The perforations also can
be formed to provide variable lengths of wrapping dunnage as
needed. By stopping the feed mechanism 20 and continuing to drive
the connecting mechanism 22, the machine 16 can burst the stock
material at the perforations to separate a length of wrapping
material from the strip of dunnage. The stock material
alternatively may be pre-cut to form discrete sheets of the desired
length, or as shown in the illustrated embodiment, the conversion
machine 36 may include a cutting mechanism 44 downstream of the
connecting mechanism 42 for cutting a desired length from the
connected strip of dunnage 73.
[0086] An exemplary cutting mechanism 44 includes a rotatable
cutting wheel 90 movable across the path of the sheet stock
material and a stationary blade 92 against which the cutting wheel
acts to cut the crumpled strip of dunnage 73 therebetween. Other
cutting mechanisms may be used in place of or in addition to the
illustrated cutting mechanism 44 to separate a dunnage product 100
from the connected strip 73.
[0087] The feed mechanism 40 and the connecting mechanism 42 may be
enclosed partially or completely within a housing (not shown). In
which case, to facilitate loading a new supply of stock material
into the conversion machine 16 or for maintenance, the housing may
be openable to access the feed mechanism 40 and the connecting
mechanism 42. In fact, one of the upper or lower rotating members
60 and 61 of the feed mechanism 40 and the respective upper or
lower gear member 70 and 71 of the connecting mechanism 42 may be
connected to an openable portion of the housing to separate the
rotating members 60 and 61 and separate the gear members 70 and 71
to facilitate access to the path of the stock material through the
conversion machine 16 along which it is converted into a dunnage
product 100.
[0088] The resulting dunnage product 100, shown in FIG. 7, includes
at least one, and preferably a plurality, of laterally-spaced,
longitudinally-extending connecting bands 102 where the sheet stock
material is embossed or pierced or punched or otherwise connected
to hold multiple plies 104 and 106 of stock material together. The
stock material generally is compressed in these connecting bands
102 and thus the crumpled plies 104 provide relatively greater loft
in cushioning regions 110 outside the connecting bands 102.
[0089] In a wrapping product that has an uncrumpled ply 106, the
uncrumpled ply acts as a carrier for the crumpled ply. If the same
width of stock material is used for the uncrumpled ply 106 and the
one or more crumpled plies 104, the crumpling process generally
will reduce the width of the crumpled ply or plies 104 such that
the uncrumpled carrier ply 106 will extend laterally beyond the
laterally-outer edges of the crumpled ply or plies 104. These
laterally-outer portions also may be folded inwardly into the
connecting bands 102 before or after being connected to further
stiffen the dunnage product lengthwise, provide a more consistent
finished edge and/or to improve the quality of the connection
between the multiple layers of stock material.
[0090] Additionally, if more than one uncrumpled ply 106 is
desired, the additional uncrumpled sheet or sheets may be fed into
the connecting mechanism 36 (FIG. 2) on the same side or on
opposing sides of the crumpled sheet or sheets. The random
crumpling of the crumpled ply or plies 104 and the laterally-spaced
connecting bands 102 holding the uncrumpled ply or plies 106 to the
crumpled ply or plies 104 provides a high quality dunnage
product.
[0091] Changing the number of crumpled sheets, the weight of the
stock material employed, or the use of either a crumpled or an
uncrumpled carrier sheet can be used to vary the cushioning or
other properties of the wrapping product. Cushioning properties
also can be controlled by changing a ratio of the feed rate of the
stock material through the feed mechanism 40 and the connecting
mechanism 42. Adjusting the gap between laterally-spaced bunching
guides also can change the final wrapping product.
[0092] Referring back to FIG. 5 for a moment, in an exemplary
operation multiple sheets P.sub.1, P.sub.2 and P.sub.3 of stock
material are fed from the supply 46, at least one sheet, and in the
illustrated embodiment two sheets P.sub.1 and P.sub.2, are
laterally-inwardly bunched in the bunching assembly 38 and advanced
by the feed mechanism 40 through the pulling feed wheels 60 and 61
toward the connecting gears 70 and 71. Because the connecting
mechanism 42 rotates the gears 70 and 71 at a slower rate than the
feed wheels 60 and 61, the stock material will longitudinally bunch
up in the tunnel 80 connecting the two, thereby creating random
crumples or folds in the stock material. The connecting mechanism
42 pulls the crumpled sheets P.sub.1 and P.sub.2 of stock material
therebetween, along with an uncrumpled carrier sheet P.sub.3, if
any, that bypassed the feed mechanism 40, and connects the multiple
sheets P.sub.1, P.sub.2 and P.sub.3 together as the overlying plies
pass between the connecting gears 70 and 71. Finally, if a cutting
mechanism 44 is employed, a desired length of dunnage is cut from
the connected strip 73 of dunnage to provide a dunnage product 100
(FIG. 7) with the desired length.
[0093] In operation, paper or other sheet stock material P.sub.1,
P.sub.2, and P.sub.3 flows from a supply 12 thereof, for example
from a roll or a stack, through a bunching assembly 24. In this
assembly, the stock material is bunched toward the center so as to
reduce the width of the web of stock material. In the feed
mechanism 20, a series of rollers or wheels feed the
inwardly-bunched stock material toward a connecting mechanism 22.
These feed wheels rotate faster than gears in the connecting
mechanism 22, however, thereby retarding the advance of the stock
material and causing the stock material to randomly longitudinally
fold, crumple, and/or roll. Unlike the shapes formed between
pleating rollers, however, the crumpled folds formed during the
crumpling operation are irregular and randomly oriented, although
generally falling within a range of widths or lengths. The height
or width of the folds or crumpled portions can be controlled by
adjusting the gap between the bunching guides. As the stock
material is fed through the feed and connecting mechanisms 20 and
22, the crumpled folds are creased, crimped, or otherwise fixed
along relatively narrow lines of connection to maintain their
crumpled nature and provide loft in the dunnage product. This
action forms the finished dunnage product, which then can be cut to
a desired length.
[0094] In summary, a dunnage conversion machine 36 converts a sheet
stock material into a dunnage product that is relatively thicker
and less dense than the stock material, but is relatively thin and
sufficiently flexible to function as a protective wrap. The
conversion machine 36 includes a feed mechanism 40 that advances a
sheet stock material therethrough and a connecting mechanism 42
downstream of the feed mechanism 40. The connecting mechanism 42
retards the passage of the sheet stock material therethrough by
feeding the stock material therethrough at a slower rate than the
feed mechanism 40 feeds the stock material to the connecting
mechanism 42. This causes the stock material to randomly crumple in
a longitudinal space between the feed mechanism 40 and the
connecting mechanism 42. The connecting mechanism 42 connects
multiple overlapping layers of sheet stock material together as
they pass therethrough, including connecting at least one crumpled
sheet to one side of one other sheet. The other sheet can be
advanced through the feed mechanism 40 and crumpled, or guided
around the feed mechanism 40 to the connecting mechanism 42 to be
connected to the crumpled sheet or sheets.
Alternative Wrappable Dunnage Converter
[0095] FIGS. 8-10 show another embodiment of a dunnage conversion
machine 200 provided in accordance with the present invention. The
conversion machine 200 converts a sheet stock material into a
wrapping dunnage product, and includes a supply of sheet stock
material 202, a feed assembly 204 that draws multiple plies P.sub.1
and P.sub.2 of sheet stock material from the supply, and a
connecting assembly 206 that connects the plies together to form a
strip of dunnage 207. The connecting assembly 206 passes the plies
or sheets of stock material therethrough at a slower rate than the
rate at which the plies are fed from the feed assembly 204, thereby
cooperating with the feed assembly 204 to cause the stock material
to randomly crumple between the feed assembly 204 and the
connecting assembly 206. A cutting assembly 208 downstream of the
connecting assembly 206 severs discrete lengths of a wrapping
dunnage product 209 from the strip 207. These components similar to
the corresponding components of the preceding embodiment, except as
noted. For example, the illustrated conversion machine 200 does not
employ the bunching assembly 38 (FIG. 1) of the previous
embodiment.
[0096] Between the supply 202 and the feed assembly 204, the
conversion machine 200 includes a series of three bars or rollers
210, 212, and 214 with axes that are aligned in parallel and in a
common plane that is inclined relative to the downstream direction.
These rollers 210, 212, and 214 define a serpentine path for the
sheet stock material as it travels from the stock supply 202 to the
feed assembly 204. These rollers can be used in conjunction with a
fan-fold supply of sheet stock material to provide a relatively
consistent tension on the stock material coming from the supply or
supplies, particularly when the supply includes a fan-folded stock
material. The rollers also provide better tracking, so that the
stock material enters the feed assembly 204 in a more consistent
lateral location.
[0097] The illustrated conversion machine 200 produces an at least
two-ply wrapping dunnage product 209. After the serpentine rollers
210, 212, and 214, both plies P.sub.1 and P.sub.2 enter the feed
assembly 204. As in the previous embodiment, the feed assembly 204
includes upper and lower rotating member 216 and 218 that form
pairs of laterally-spaced rotating members, in this case wheels.
The alternative arrangements described above also can employed in
this embodiment. The upper rotating members 216 engage and advance
an upper ply of sheet material and the lower rotating members 218
engage and advance a lower ply of sheet material. The rotating
members 216 and 218 in this embodiment are mounted on common
laterally-extending shafts, and the upper rotating members 216 are
pivotably mounted and biased against the lower rotating members
218.
[0098] At an upstream end of the feed assembly 204 at least one ply
is separated from at least one other ply. Typically only two plies
P1 and P2 are used, and the two plies follow different paths into
the feed assembly 204. This is accomplished with a separator 220
having a round upstream end 222 and a plate member 224 extending
therefrom in a downstream direction into the feed assembly 204 and
between two pairs of laterally spaced-apart rotating members or
wheels 216 and 218 that form part of the feed assembly 204. These
rotating member pairs 216 and 218 are laterally spaced on opposite
sides of the separator plate or engage one another through
laterally-spaced openings in the separator plate.
[0099] Above and below the separator plate 224, upper and lower
channel guide member 226 and 228 or channel guide plates define a
path through the feed assembly 204 and the connecting assembly 206.
These channel guides 226 and 228 define the upper and lower
boundaries that confine the sheet stock material therein to
facilitate the crumpling of the stock material between the feed
assembly 204 and the slower speed connecting assembly 206. The
sides of this pathway are bounded by opposing laterally-spaced
frame members 230 and 232, which also support the transverse shafts
of the feed assembly 204 and the connecting assembly 206 in this
embodiment. In addition, the separator plate 224 generally is
parallel to the upper and lower guide members 226 and 228, but is
closer to one of the guide members. Consequently, the stock
material passes on either side of, in this case above and below the
separator plate 224, whereby the stock material on either side will
fold and crumple asymmetrically. This asymmetrical folding and
crumpling yields two different crumpled sheets generally having
waveforms with independent frequencies and amplitudes in the
irregular crumpling of the sheet material. Accordingly, the
different size ply in-feed chambers or passages defined by the
channel guides 226 and 228 and the separator plate 224 allow the
plies to randomly crumple with different frequencies and amplitudes
so the plies are less likely to interlock when they are brought
together, thereby providing more loft after the plies are
connected. Without the separator plate 224, the plies would nest
into each other to create a thinner, less supportive dunnage
product.
[0100] After the feed assembly 204, the separator plate 224 ends
and the upper and lower channel guide plates 226 and 228 converge
adjacent the conversion assembly 206. This causes the separate
plies to come together and become connected to one another as they
pass through the connecting assembly 206 together. And while the
upper and lower channel guides 226 and 228 define a converging
space at the upstream side of the connecting assembly 206, the
channel guides do not have to converge and can continue straight,
all the way through the connecting assembly 206 without reducing
the volume of the passage for the stock material.
[0101] Although this embodiment lacks the bunching assembly 38
(FIG. 1) of the previous embodiment, the illustrated conversion
machine 204 includes laterally spaced-apart forming plow 234
between the feed assembly 204 and the connecting assembly 206 that
reduce the width of the stock material and inwardly fold the free
lateral edges as the stock material passes thereby. The forming
plows 234 each have a curved surface that is mounted to extend into
the path of the lateral edges of the stock material, gradually
protruding further inward toward a downstream end thereof. As the
lateral edges of the stock material are folded or turned inwardly
by the lateral plows 234, the edges of the stock material of one
layer can fold around and enclose the edges of the other layer, and
the connecting assembly 206 then mechanically connects the
overlapping layers together. This makes the lateral edges of the
finished dunnage product more uniform, and the additional folding
and the resulting additional layers passing through the connecting
assembly 206 to form the connecting lines helps to hold the dunnage
product together better. The conversion machine 200 defined by this
feed assembly 204 and connecting assembly 206 provides
approximately 40-55% crimp loss. This means that the wrap dunnage
product that is produced is approximately 40-55% shorter than the
stock material that is used to produce it.
[0102] The connecting assembly 206, like the feed assembly 204,
includes two pairs of laterally spaced-apart rotating gear members
or gears 236 and 238 that are biased together and connect the
overlapped layers of stock material as the stock material passes
between the gears. Alternative arrangements described with respect
to the previous embodiment also are contemplated for this
embodiment. Upper gears 236 are biased against lower gears 238 by a
biasing member, such as a spring. The biased rotating members 216,
218 of the feed assembly 204 and the biased gears 236 and 238 of
the connecting assembly 206 are each mounted in a cantilever
fashion for rotation about respective pivots 240 and 241 so that a
smaller spring can be used to provide sufficient biasing force.
[0103] In the illustrated conversion machine 200, the feed assembly
204 and the connecting assembly 206 are driven by a common electric
drive motor 242. The drive motor 242 positively drives the lower
rotating members 218 of the feed assembly 204 and is connected to
the lower gear members 238 of the connecting assembly 206 via a
chain and suitable sprocket (not shown). The ratio of the speed
between the rotating members 216 and 218 of the feed assembly 204
and the gears 236 and 238 of the connecting assembly 206 can
readily be adjusted by adjusting the relative sizes of the
sprockets and providing a suitable chain therebetween.
Alternatively, separate motors can be provided to separately drive
the feed assembly 204 and the connecting assembly 206. A
transmission also may be provided instead of the illustrated chain
drive, to provide the ability to change the relative speeds of the
feed wheels 216 and 218 and the gears 236, 238 without interrupting
their operation.
[0104] A separate cut motor 244 drives a guillotine-style cutting
assembly which includes a cutting blade 246 that extends across the
width of the path of the dunnage strip and has a pair of crank arms
248 aligned with the laterally-spaced rotating members 216 and 218
of the feed assembly 204 and the gears 236 and 238 of the
connecting assembly 206 to positively drive the cutting blade 246
through the layers of crumpled stock material with the most force
applied at the lines of connection. The crank arms 248 are
connected to a common shaft 250 and rotate through a cycle defined
by respective cams 252. As noted above, the stock material could be
perforated so that a length of wrapping dunnage can be torn from
the strip of dunnage.
[0105] As shown in FIG. 11, the resulting wrapping dunnage product
209 includes two plies 262 and 264 of randomly crumpled sheet stock
material. Although the exact variation in the crumpled undulations
is unpredictable, the amplitude and frequency of the undulations
generally can be approximately predicted statistically, and is the
result of the differential speed of the rotating members 216 and
218 of the feed assembly 204 and the gears 236 and 238 of the
connecting assembly 206, and the size of the respective channels
between the separator plate 224 and the channel guide plate 226 or
228 bounding the other side of the space through which a respective
ply 262 or 264 travels (see FIG. 9). Because the gap is different
on each side of the separator 220, the frequency F.sub.1 and
amplitude A.sub.1 of the upper ply 262 relative to the frequency
F.sub.2 and the amplitude A.sub.2 of the lower ply 264 generally
are different. The differential crumpling keeps the two plies 262
and 264 from nesting with one another when they come together,
thereby retaining loft in the resulting dunnage wrap 209.
Another Wrappable Dunnage Converter
[0106] Yet another exemplary dunnage conversion machine 300 is
shown in FIGS. 12-15. This conversion machine is consistent with
the schematic representation of the dunnage conversion machine 200
of FIG. 9. Unless specified, features of this conversion machine
300 are substantially similar or the same as those of one or both
of the previous embodiments. While the basic operation of this
conversion machine is similar to that described with regard to the
previous two embodiments, this conversion machine includes several
features that make it easier to load and less likely to jam.
[0107] An exemplary packaging system 322 shown in FIG. 12 includes
the conversion machine 300, the conveyor 318 for transporting
containers 324 to a packaging location adjacent the outlet 316, and
a control sensor 326 mounted adjacent the conveyor 318 at a
position upstream of the conversion machine 300.
[0108] By measuring and/or inputting the conveyor speed, a
controller 330 incorporated into the conversion machine 300 or
remote from the conversion machine 300 can use a signal from the
control sensor 326 to trigger a timer. The length of time from when
the sensor 326 is triggered until a container 324 on the conveyor
318 is no longer sensed by the sensor 326 can be used to determine
the length of the container 324 and thereby the length of an
appropriate wrapping dunnage product. The controller 330 can
automatically determine the appropriate length and control the
conversion machine 300 to dispense the wrapping dunnage product
directly to the container.
[0109] A suitable application for such a system 322 would arise
when a wrapping dunnage product will be used as a bottom or top
layer in the container. Consequently, the production of a wrapping
dunnage product for layering in a container can be automated and a
wrapping product of the appropriate length can be provided
automatically and on demand in a more compact configuration than a
pre-produced supply of wrapping dunnage material.
[0110] The conversion machine 300 generally includes a housing 302
that surrounds or incorporates both a conversion assembly that
includes a feed assembly 304 and a connecting assembly 306, and a
cutting assembly 306. The conversion machine 300 also includes the
forming plows 312 between the feed assembly 304 and the connecting
assembly 306 that were described with reference to the previous
embodiment. The housing 302 is mounted to a stand 314 to raise an
outlet 316 of the housing 302 above a packaging surface. In the
illustrated embodiment the packaging surface includes a conveyor
318. The housing 302 is pivotable about an axis 320 to direct the
wrapping product to output in a desired direction.
[0111] An exemplary stock supply assembly 332 in this system 322
supplies two plies P.sub.1 and P.sub.2 to the dunnage conversion
machine 300. To facilitate supplying two plies or webs of sheet
stock material to the conversion machine 300, an exemplary stock
supply 332 includes a stand 334 (FIGS. 16 and 17) for supporting
two separate stacks of fan-fold sheet stock material. An exemplary
stand is shown in FIGS. 16 and 17. The stand 334 includes a base
336, a pair of spaced-apart upright frame members 340 having
cross-members 342 to hold the upright members 340 upright, and
transverse bars or rollers 344 spanning an upper portion of the
upright members 340 to help guide the stock material to the
conversion machine 300 (FIG. 12). The upright members 340 define
opposing substantially-open sides 343 that facilitate loading
stacks of fan-fold stock material therein. Lower regions of the
open sides 343 include inwardly-extending supports 346 to help
support a stack. Additionally, a central portion 350 of the upright
members 346 protrudes inwardly to support an opposing side of the
stack and separate the two supplies or stacks. These
inwardly-extending and inwardly-protruding portions 346 and 350 of
the upright members 340 also stiffen the upright frame members 340.
Additionally, the illustrated stand 334 is provided with wheels 352
for mobility so that it also functions as a cart.
[0112] From the stand 334 or other supply 332, each ply P.sub.1 and
P.sub.2 passes through separate sets of serpentine guides 354,
shown in FIGS. 13-15 and particularly FIG. 18. The serpentine
guides 354 provide both adequate tension and encourage proper
tracking of each ply as it enters the feed assembly 304. The
serpentine guides 354, mounted at the upstream end of the
conversion machine 300, define serpentine paths for each ply of
stock material and include an upper set of three rollers 356, 358,
and 360 that define a serpentine path for an upper ply of stock
material and a lower set of three rollers 366, 368, and 370 that
define a serpentine path for a lower ply of stock material. The
axes of the rollers in each set generally are provided in
respective planes that are angled relative to the downstream
direction. As a result, each ply P.sub.1 and P.sub.2 has a direct
path from the outlet adjacent the downstream-most rollers 360 and
370 of each set to upper or lower wheels 372 and 374 of the feed
assembly 304.
[0113] The center roller 358 and 368 of each set is mounted between
a pair of swing arms 376. The swing arms 376 are rotatable about
pivots 380 between an operating position in-line with the other
rollers 356 and 360 or 366 and 370 and a loading position removed
from the operating position. The loading position provides a large
passage between the center roller and the other two rollers so that
the stock material can be fed between the rollers more easily.
Loading then becomes a simple task of laying the stock material
over the two rollers and under the center roller and into the feed
assembly 304. Then the operator can push the center roller back
down to its aligned operating position, thereby weaving the stock
material into an undulating or serpentine path through the three
aligned rollers. Grab bars 382 and 383 attached to the swing arms
376, parallel to and spaced from the center roller 358 or 368,
facilitates manually moving the center roller out of line with the
other rollers to the loading position and then back to the
operating position in line with the other rollers. The central
roller can be secured in the operating position, such as by using a
spring-loaded element that engages a detent (not shown).
[0114] From the serpentine guides 354, each ply P.sub.1 and P.sub.2
enters the feed assembly 304 on a respective side of a separator
plate 384 that extends between the wheels 372 and 374 of the feed
assembly 304 and defines a passage for each ply P.sub.1 and P.sub.2
between upper and lower channel guides 386 and 388. The channel
guides 386 and 388 flare outward, away from one another, at an
upstream end to receive the plies, and then extend parallel to each
other through the feed assembly 304 and the connecting assembly 306
to guide the stock material therethrough to the cutting assembly
310. As noted previously, the channel guides 386 and 388 also
confine the stock material between the feed assembly 304 and the
connecting assembly 306.
[0115] The feed assembly 332 includes laterally-spaced upper and
lower pairs of rotating members or wheels 372 and 374, and a wheel
lifter to separate the upper and lower wheels 372 and 374 to
facilitate loading a new supply of sheet stock material. Unlike the
separately-supported upper wheels 216 (FIG. 10) of the preceding
feed assembly, the upper wheels 372 in the feed assembly 304 shown
in FIGS. 12-15 are secured to a common shaft 390.
[0116] Referring now to FIGS. 19-22, the wheel shaft 390 is
supported at its lateral ends by a pair of opposing housing blocks
392 mounted outside the lateral side plate frame members 394, a
pair of lifting plates 396 inward of the housing blocks 392, and a
lifting cam shaft 400. Each housing block 392 houses a compression
spring 402 to bias the upper and lower rotating members or wheels
372 and 374 toward one another. The housing block 392 has a recess
or pocket 404 that receives an end of the lifting cam shaft 400 and
holds it in place, and through-slots 406 that allows the wheel
shaft 390 to translate vertically on parallel guides. The wheel
shaft 390 has a hole 410 near its end where a bolt 408 passes
through to act as a spring compressor as well as the guide for
linear movement of the wheel shaft 390.
[0117] The lifting cam shaft 400 is in-line with, parallel to, and
above the wheel shaft 390 in the illustrated embodiment. The
lifting shaft 400 spans the full width of the feed assembly 304 and
its lateral ends are captured within the pockets 404 in the housing
blocks 392. One side of each end of the lifting cam shaft 400 is
milled down to a flat 411 such that the lifting cam shaft 400 sits
below its tangency on the flats 411 in the pockets 404 of the
housing blocks 392. The lifting plates 396 have a clearance hole
for the cam shaft 400 and a slot for the wheel shaft 390 to allow
the translation motion of the wheel shaft therein.
[0118] A hole toward the center of the lifting cam shaft 400
receives a lever arm 412 that can extend outside the housing 302 of
the conversion machine 300. The hole and the lever arm 412 are
parallel to the flats 411 in the illustrated embodiment. Rotating
the lever arm 412 through ninety degrees from an operating position
to a loading position rotates the ends of the cam shaft 400 off
their flats 411 onto their round portions. The lifting plates 396
transfer this rotational motion to the wheel shaft 390, and thus to
the upper rotating members or wheels 372, thereby providing a gap
between the upper and lower wheels 372 and 374, between which the
sheet stock material can be fed without obstruction all the way to
rotating gears 414 and 416 in the connecting assembly 306 (FIG.
15). Once the stock material is loaded, returning the lever arm 412
to its operating position closes the gap between the upper and
lower wheels 372 and 374 of the feed assembly 304. In the operating
position, the spring 402 biases the shaft 390 of the upper wheels
372 toward against the lower wheels 374, now with the stock
material therebetween.
[0119] As mentioned above, the conversion machine 300 includes
forming plows 312 shown in FIGS. 13-15 of essentially the same
shape as in the previous embodiment, mounted between the feed
assembly 304 and the connecting assembly 306 to urge inwardly
lateral edge portions of the sheet stock material. The lateral edge
portions of one ply also may turn or fold over the edge portions of
another ply, and the resulting increased number of layers will be
connected together as they pass between the gears 414 and 416 of
the connecting assembly 306.
[0120] Referring now to FIGS. 23 and 24, to assist the channel
guide plates 386 and 388 in guiding the crumpled stock material
past the gears 414 and 416 in the connecting assembly 306, the
conversion machine 300 employs stripper bars 418 and 419 to strip
crimped stock material from between the teeth of the gears 414 and
416 to minimize or prevent jamming of the stock material in the
gears 414 and 416. Each stripper bar 418 and 419 extends through an
annular recess or valley between laterally-spaced gear segments
422. Because the stripper bars 418 and 419 are smaller than the
space between the gear shafts 421 and 423 and the diameter of the
gears 414 and 416 between the gear teeth, and passes the gear at a
point adjacent the shaft, they do not interfere with the connecting
operation in any way. The upper strippers 418 on the biased idler
gears 414 are attached to a gear support 424 upstream and
downstream of each gear 414, allowing the stripper bars 418 to move
with the pivotable gear support 424 while still providing the
necessary stripping action in a central portion of the gear 414.
The lower stripper member 419 is fixed and does not move, since the
lower gear 416 only rotates.
[0121] As in the previous embodiment, the feed assembly 304 and the
connecting assembly 306 are driven by a common drive motor 430. The
drive motor 430 is connected to the lower wheels 374 of the feed
assembly 304 and the lower gears 416 of the connecting assembly 306
via a drive chain 432 and respective sprockets 434 and 436, as seen
in FIG. 25. Since the drive sprockets 434 and 436 that are used to
drive the wheels 372 and 374 of the feed assembly 304 and the gears
414 and 416 of the connecting assembly 306 are located outside the
side plate frame members or walls 394, the sprockets 434 and 436
are readily accessible. Changing the chain 432 and a sprocket 434
and 436 are the only items necessary to change the amount of crimp
loss and average crumpling frequency. While this approach is
relatively simple and inexpensive, the machine can alternatively
include a transmission and/or separate motors to control the
relative speeds on the fly, without stopping the conversion
process. As noted above, the relative amplitude of the crumpling
generally is defined by the separator plate 384 and its distance
from the upper and lower guide plates 386 and 388 (FIG. 15).
[0122] The connected strip of dunnage exiting the connecting
assembly 306 passes downstream to the cutting assembly 310. The
cutting assembly 310 in this embodiment is shown in FIGS. 26 and 27
and is similar to the cutting assembly 208 (FIG. 9) in the previous
embodiment. The cutting assembly 310 includes a guillotine-style
cutting blade 440 whose movement is directed by a twin four-bar
linkage 442 and a slider assembly 444. A separate cut motor 445
drives the four-bar linkage 442 via a gear box 446. A drive shaft
448 symmetric about the gear box 446 has a drive crank 450 on
opposing ends of the shaft 448. Each drive crank 450 is attached to
a second crank 452 which in turn attaches to a carriage 453 that
supports the cutting blade 440. The cutting blade carriage 453
rides on a pair of parallel shafts or slider arms 454 to guide the
cutting blade 440 as it moves across the path of the strip of
dunnage to sever a discrete length of a wrapping dunnage product
from the strip. Each of the crank arms 450 is aligned with one of
the laterally-spaced gear pairs 414 and 416 of the connecting
assembly 306 to concentrate the force applied to cutting the strip
of dunnage at the connecting lines, which are the areas of maximum
resistance to being cut.
[0123] The cutting blade carriage 453 has an angled surface 456
behind the blade edge. This angle removes any flat surface upon
which slivers of the cut dunnage product could rest. From the
cutting blade 440, the housing exit chute 460 continues a downward
slope out of the machine 300. This allows the next strip of dunnage
formed in series to sweep out the remnants from the previous strip
of dunnage.
[0124] Finally, this conversion machine 300 also provides two ways
to detect jams. Refer back to FIGS. 12-15. First, the controller
330 senses when the speed of the drive motor 430 falls below a set
limit compared to its intended running speed. Second, an optical
sensor 462 is mounted near the idler gear support 424 in the
connecting assembly 306. This sensor 462 has a fixed focal length,
and when the stock material backs-up, narrowing the gap between the
sensor and the original path of the stock material, the controller
330 identifies this as a jam and the controller 330 can stop the
machine 300 and output a signal to alert an operator.
[0125] These features of the dunnage conversion machine 300 make it
easier to load, improve the tension and tracking of the incoming
plies of stock material as well as the cutting of a dunnage product
from the strip, and allow the conversion machine to operate longer
without jamming, yet quickly alert an operator in the event of a
jam. All while still producing a quality wrapping dunnage product
in a compact machine on-demand in the desired length as needed.
[0126] In summary, and referring to FIG. 1, the present invention
provides a dunnage conversion machine 36 converts a sheet stock
material into a dunnage product that is relatively thicker and less
dense than the stock material, but is relatively thin and
sufficiently flexible to function as a protective wrap. The
conversion machine 36 includes a feed mechanism 40 that advances a
sheet stock material therethrough and a connecting mechanism 42
downstream of the feed mechanism 40. The connecting mechanism 42
retards the passage of the sheet stock material therethrough by
feeding the stock material therethrough at a slower rate than the
feed mechanism 40 feeds the stock material to the connecting
mechanism 42. This causes the stock material to randomly crumple in
a longitudinal space between the feed mechanism 40 and the
connecting mechanism 42. The connecting mechanism 42 connects
multiple overlapping layers of sheet stock material together as
they pass therethrough, including connecting at least one crumpled
sheet to one side of one other sheet.
Sliding Stock Supply Shelf
[0127] The present invention also provides a dunnage conversion
machine having a shelf for supporting a supply of stock material, a
conversion assembly for converting stock material into a dunnage
product dispensed through an outlet in a downstream direction, and
a stand that supports the conversion assembly and the shelf. The
shelf is linearly movable between an operating position adjacent
the conversion assembly and a loading position spaced from the
operating position for loading stock material without moving the
conversion assembly.
[0128] Referring now in detail to the drawings and initially to
FIGS. 28-30, the present invention provides a dunnage conversion
machine 1000 for producing dunnage products for use in packing
objects in a container. The conversion machine or converter 1000
includes a dunnage conversion assembly 1002 for converting a stock
material 1004 into a dunnage product 1006 and a stand 1010 that
supports the conversion assembly 1002.
[0129] The conversion assembly 1002 is capable of converting the
stock material 1004 into a dunnage product 1006 as the stock
material moves through the conversion assembly in an
upstream-to-downstream direction, from an upstream end 1014 to a
downstream end 1016. The converter 1000 typically includes a
housing 1022 for the conversion assembly 1002. The conversion
assembly 1002 dispenses the dunnage product 1012 through an outlet
1020 defined by a downstream end of the housing 1022. Any type of
conversion assembly that converts a stock material into a
relatively less dense dunnage product can be used in accordance
with the present invention. An exemplary conversion assembly is
disclosed in U.S. Pat. No. 6,676,589, which is hereby incorporated
by reference.
[0130] The stand 1010 includes a frame 1024 with uprights 1026 for
supporting the conversion assembly 1002 at an elevated position,
and can also include one or more wheels 1030 to help transport the
converter 1000.
[0131] In addition to the conversion assembly 1002, the stand 1010
also supports a shelf 1032 for supporting a supply of stock
material 1004. The shelf 1032 defines a horizontal, substantially
flat and continuous surface for supporting the supply of stock
material.
[0132] The stock material 1004, such as a container of stock
material or a stack of fan-folded sheet stock material is supported
on the shelf 1032 to be fed into the conversion assembly 1002 for
conversion into a dunnage product 1006. An exemplary stock material
1004 includes one or more stacks of fan-folded kraft paper. The
stock material 1004 supported on the shelf 1032 can be fed into the
upstream end 1014 of the conversion assembly 1002 for conversion
into dunnage products 1006.
[0133] The shelf 1032 is linearly movable between a working or
operating position (FIG. 29) adjacent the conversion assembly 1002
and a loading position (FIG. 30) spaced from the operating position
for loading stock material without moving the conversion assembly
1002. The illustrated stand 1010 supports the conversion assembly
1002 above the shelf 1032. In the operating position, the shelf
1032 is under the conversion assembly 1002.
[0134] In the illustrated converter 1000, the shelf 1032 is mounted
to the stand 1010 by a pair of parallel, spaced apart, telescoping
support and guide members 1034, such as commonly available drawer
slides. Both the outlet 1020 of the conversion assembly 1002 and
shelf 1032 in the loading position are on the same side of the
conversion machine 1000. The packer or other operator both can
retrieve dunnage products 1006 from the outlet 1020 and load the
stock material 1004 from the downstream end 1016 of the converter
1000. This is advantageous when space is limited, such as when the
conversion assembly 1002 is positioned underneath a table 1036 or
other work surface as shown in FIG. 28. This allows an operator to
more efficiently supply stock material, splice a new supply of
stock material to an almost-spent supply stock material, and/or
return to a packing operation as quickly as possible.
[0135] An exemplary method of loading a dunnage conversion machine
100 thus includes the following steps: (a) linearly moving the
shelf 1032 from the operating position (FIG. 29) to the loading
position (FIG. 30) without moving the conversion assembly 1002, (b)
loading a supply of stock material 1004 onto the shelf 1032, and
(c) returning the shelf 1032 to the operating position (FIG. 29).
The method can also include the step of splicing a new supply of
stock material to an almost-spent supply of stock material before
the step of (c) returning the shelf 1032 to the operating
position.
Short-Dunnage Output Chute Bypass
[0136] In the place of or in addition to the shelf, the conversion
machine can include an output chute with an upstream end that is
moveable relative to the outlet. In a first position, the output
chute is aligned with the outlet to receive dunnage products, and
in a second position the upstream end of the output chute is moved
out of alignment with the outlet so that dunnage products from the
conversion assembly bypass the output chute.
[0137] To dispense dunnage products with lengths both under and
over a minimum length to prevent jamming in a typical output chute,
the present invention provides an output chute that can be moved
out of the way to dispense relatively short dunnage products along
a separate path that does not go through the output chute.
[0138] Turning now to FIGS. 31-38 an exemplary dunnage conversion
machine or converter 1100 is shown. The converter 1100 includes a
conversion assembly 1154 that converts a stock material 1156 into a
dunnage product 1160 as the stock material travels from an upstream
end 1162 of the conversion assembly 1154 to a downstream end 1164
in an upstream-to-downstream direction 1166. Any conversion
assembly that is capable of producing dunnage products of multiple
lengths can be used in the converter 1100 provided by the
invention.
[0139] The converter 1100 includes a housing 1168 for a conversion
assembly 1154. A downstream end of the housing 1168 defines an
outlet 1170 for the conversion assembly 1154. The conversion
assembly 1154 dispenses dunnage products 1160 through the outlet
1170 in a downstream direction 1166. The distance between the
downstream end of the conversion assembly 1154 and the outlet 1170
is less than a predetermined minimum dunnage product length. In an
exemplary embodiment, the outlet 1170 defined by the housing 1168
is less than five centimeters downstream of a downstream end of the
conversion assembly 1154.
[0140] The converter 1100 also includes a chute 1172 adjacent the
outlet 1170. The chute 1172 has a gravity chute portion 1190 that
extends in a direction transverse the downstream direction 1166,
and an output chute portion 1192, also referred to more simply as
the output chute. The output chute portion 1192 is movable between
a first position (FIG. 32) where an upstream end of the output
chute portion 1192 is aligned with the outlet 1170, and a second
position (FIG. 33) where the upstream end of the output chute 1192
is spaced from the outlet 1170 and its first position so that
dunnage products exiting the outlet 1170 bypass the output chute
portion 1192. The conversion assembly 1154 is operative whether the
output chute 1192 is in either the first position or the second
position.
[0141] The gravity chute portion 1190 has an entrance 1194 adjacent
the outlet 1170. The output chute portion 1192 closes the entrance
1194 to the gravity chute 1190 when the output chute portion 1192
is in the first position (FIG. 32) and opens the entrance 1194 to
allow dunnage products 1160 to enter the gravity chute portion 1190
when the output chute portion 1192 is in the second position (FIG.
33). The gravity chute 1190 has an exit 1196 for retrieving dunnage
products that is at least 750 millimeters from the conversion
assembly outlet 1170. In the embodiment shown in FIGS. 32 and 33, a
bin or tray 1198 below the gravity chute portion 1190 receives and
holds the relatively short dunnage products 1200 that fall through
the gravity chute 1190.
[0142] The converter 1100 further includes a controller 1202 that
enables selection of a desired length of dunnage products and
controls the position of the output chute 1192. The controller 1202
typically includes a processor 1204, a memory 1206, and a program
stored in the memory. The controller 1202 also includes one or more
input devices 1210 for determining the selected length and one or
more outputs for controlling elements of the conversion assembly
1154 and movement of the output chute 1192. The input devices 1210
can be connected to or include one or more of a keyboard, mouse,
touch screen display, a scanner or sensor, a bar code reader for
reading a bar code on a container that receives the dunnage
products, a radio frequency identification device (RFID) sensor,
microphone, camera, etc. The controller 1202 can be programmed to
recognize the appropriate inputs that represent a selected length
or identify a location to look up one or multiple lengths needed
for a particular packing container.
[0143] The outputs from the controller 1202 can control various
motors that drive elements of the conversion assembly 1154 and/or
movement of the output chute 1192. In the embodiment shown in FIGS.
34-38, the controller 1202 controls a solenoid motor 1212 and a
linkage 1214 to move the output chute 1192 from the first position
(FIG. 34) to the second position (FIG. 37).
[0144] Converters often are located near a conveyor 1220 (FIG. 31)
that transport packaging containers to be packed and shipped. Other
work surface also are used for packing.
[0145] In the embodiment shown in FIGS. 34-38, the gravity chute
portion 1190 has been omitted to improve the view of the outlet
1170 (FIGS. 37 and 38) and the output chute 1192. The output chute
1192 has walls 1220 that define a passage 1222 through the output
chute. The output chute 1192 is movable between a first position
where the output chute 1192 and the passage 1222 through the output
chute 1192 are aligned with the outlet 1170 to receive relatively
longer dunnage products 1124. In the first position, dunnage
products 1224 having a length of at least a predetermined minimum
length that are dispensed through the outlet 1170 enter the output
chute 1192. And in the second position, the output chute 1192 is
not aligned with the outlet 1170, so relatively short dunnage
products 1200 having a length less than the predetermined minimum
length that are dispensed through the outlet 1170 bypass the output
chute 1192.
[0146] In the second position, a bottom surface 1230 of the output
chute 1192 defines a guide surface to direct the dunnage products
bypassing the output chute downward. The bottom of the output chute
1192 or guide surface 1230 is horizontally spaced downstream from
the outlet 1170 and transverse a path of the dunnage products 1200
exiting the outlet 1170 in the downstream direction 1160. As the
dunnage products 1200 exit the outlet 1170, if a leading edge
extends far enough to engage the bottom 1230 of the output chute
1192, the inclined surface directs the dunnage products 1200
downward. As the dunnage products 120 clear the outlet 1170, they
fall through the gravity chute 1190 (FIG. 32) for collection below
the outlet 1170.
[0147] In the illustrated embodiment, the output chute 1192 is
pivotable about an axis 1232 spaced from the outlet 1170 in the
housing 1168, so that in the second position an upstream end of the
output chute 1192 is rotatably spaced from the outlet 1170 and
spaced from the position of the upstream end of the output chute
1192 in the first position. The pivot axis 1232 is substantially
parallel to the plane of the outlet 1170, generally is horizontal,
and generally is near the downstream end of the output chute
1192.
[0148] An exemplary method of dispensing dunnage products provided
by the present invention includes the steps of: (a) converting a
stock material into a dunnage product and dispensing the dunnage
product through an outlet, (b) if the dunnage product has at least
a predetermined minimum length, moving an upstream end of an output
chute adjacent to and in alignment with the outlet to receive,
support, and guide the dunnage product as it exits the outlet, and
(c) if the dunnage product has a length that is less than the
predetermined minimum length, moving the upstream end of the output
chute relative to the outlet so that dunnage products exiting the
outlet bypass the output chute.
[0149] In summary, the present invention provides a dunnage
conversion machine that includes a shelf for supporting a supply of
stock material, a conversion assembly for converting stock material
into a dunnage product dispensed through an outlet, and a stand
that supports the conversion assembly and the shelf. The shelf is
linearly movable between an operating position adjacent the
conversion assembly and a loading position spaced from the
operating position for loading stock material without moving the
conversion assembly. In the place of or in addition to the shelf,
the conversion machine can include an output chute with an upstream
end that is moveable relative to the outlet. In a first position,
the output chute is aligned with the outlet to receive dunnage
products, and in a second position the upstream end of the output
chute is moved out of alignment with the outlet so that dunnage
products from the conversion assembly bypass the output chute.
[0150] Although the invention has been shown and described with
respect to a certain illustrated embodiment or embodiments,
equivalent alterations and modifications will occur to others
skilled in the art upon reading and understanding the 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 (i.e., that is functionally
equivalent), even though not structurally equivalent to the
disclosed structure which performs the function in the herein
illustrated embodiment or embodiments of the invention.
* * * * *