Product packaging system and method

Abstract

The packaging system and method supplies a dunnage product from a source to a distribution assembly for distribution to one of a selection of packaging stations. The distribution assembly comprises a closed distribution path, at least one dunnage carrier configured to transport the dunnage product along the distribution path, a plurality of control surfaces, and a dunnage deflector provided at each packaging station. Each control surface has a plurality of cam paths. The dunnage carrier comprises at least one cam follower configured to engage with one selected cam path. The dunnage deflector is also selectively operable to selectively engage with the dunnage product in the dunnage carrier to guide the cam follower to the selected cam path and transport the dunnage product to the selected packaging station.

Description

Technical Field

[0004] , , , , , , ,

[0003]

[0001] The present invention relates to a product packaging system, and more specifically to a damage pad conveying mechanism used in a packaging system together with a damage converter.

Background Art

[0002] When transporting a product from one location to another, the product is usually contained and transported in a container together with protective packaging material. The container may be a cardboard box. The protective packaging material may be a plastic airbag, a paper pad, a foam pad, or other elastic material.

[0003] A damage converter or a converter is used to convert raw materials such as a paper sheet, a plastic sheet, or a foam material into a cushioning damage product or a damage pad. The converter usually discharges the damage product from an outlet in a predetermined discharge direction, sends it out to a transfer zone such as a holding area or a staging area, and the damage product is then taken out from there for insertion into a container for packaging.

Summary of the Invention

[0004] This disclosure relates to a system and method for supplying and distributing a dunnage product to multiple packing stations. The system is characterized by a dunnage product source, a distribution assembly, and multiple packing stations, which are combined to provide a packing system and method that offers advantages over existing packing configurations. In particular, an exemplary packing system comprises a dunnage product source, multiple packing stations, and a distribution assembly that selectively distributes the dunnage product from the source to selected packing stations, so that the dunnage product is automatically supplied to the packing stations. The distribution assembly comprises one or more dunnage carriers that transport the dunnage product from the source to selected packing stations, and a control surface having a cam path that controls the opening and closing of the dunnage carrier in conjunction with a cam follower on the dunnage carrier, and recovers and discharges the dunnage product without supplying power to the dunnage carrier. The operation of the dunnage carrier is such that when the cam follower engages with the cam path, the dunnage carrier opens and closes against a biasing force, thereby simplifying the distribution assembly.

[0005] To paraphrase the claims, the exemplary packaging system comprises at least one source of dunnage products, a plurality of packaging stations, and a distribution assembly for selectively distributing the dunnage products to one packaging station selected from the sources. The distribution assembly comprises a closed distribution path, at least one dunnage carrier configured to transport the dunnage products along the distribution path, a plurality of control surfaces, and dunnage deflectors located at each source and each packaging station. Each control surface has a plurality of cam paths, one of which is located adjacent to each packaging station. The dunnage carrier comprises at least one cam follower configured to engage with one selected cam path. The dunnage deflectors at each packaging station also engage with the dunnage products in the dunnage carrier to guide the cam follower of the dunnage carrier to the selected cam path, thereby supplying the dunnage products to one of the selected packaging stations. Control surfaces are also located adjacent to the sources.

[0006] In one or more embodiments, the system further includes a controller that selectively controls the dunnage deflector at each packing station to distribute the dunnage product to one of the selected packing stations.

[0007] In one or more embodiments, the distribution assembly includes a conveyor that defines a distribution path and can transport at least one dunnage carrier along the distribution path.

[0008] In one or more embodiments, the distribution path is located above the packing station.

[0009] In one or more embodiments, the dunnage deflector of each packaging station is selectively movable between an extended position that engages with the dunnage product in the dunnage carrier and a retracted position away from the extended position.

[0010] In one or more embodiments, the source of the dunnage product includes a converter that converts a sheet-like stock material into a dunnage product with a lower density than the sheet-like stock material.

[0011] In one or more embodiments, the converter is a cushioning converter capable of converting kraft paper into a cushioning dunnage product.

[0012] In one or more embodiments, the converter is mounted on a stand at a high position.

[0013] In one or more embodiments, at least one packing station includes a receptacle for receiving and storing dunnage products until needed.

[0014] In one or more embodiments, each packaging station includes a receptacle for receiving and storing the dunnage product until needed.

[0015] In one or more embodiments, the receiver has an opening on the side near the bottom of the receiver to facilitate the removal of the dunage products in the order they were supplied.

[0016] An exemplary packaging method includes (a) a supply step of supplying a dunnage product from a source; (b) a transport step of transporting the dunnage product from the source through a distribution assembly along a distribution path having a plurality of packaging stations arranged along the distribution path; and (c) a control step of controlling the components of the distribution assembly to transport the dunnage product to one selected from the plurality of packaging stations.

[0017] In one or more embodiments, the transport step includes transporting the dunnage product within a clamping device attached to a conveyor.

[0018] In one or more embodiments, the transport step includes automatically opening a pair of jaws of the clamping device to receive the dunnage product between them as the conveyor moves the clamping device through the outlet of the supply source, and automatically closing the clamping device to capture the dunnage product between the pair of jaws as the conveyor moves the clamping device through the supply source.

[0019] In one or more embodiments, the control step includes automatically opening the clamping device as the conveyor moves the clamping device through a selected packing station.

[0020] In one or more embodiments, the control step includes controlling the movement of a dunnage deflector adjacent to each of the packing stations between an extended position and a retracted position in order to control the orientation of the dunnage product as the dunnage product is transported through each packing station.

[0021] In one or more embodiments, the control step includes controlling a damage deflector adjacent to each of a plurality of packaging stations to move between an extended position and a retracted position in order to control the orientation of the damaged product and the clamping device as the damaged product is conveyed past each packaging station, and the clamping device includes a cam follower that interacts with a cam path on a cam surface at each packaging station and controls whether the clamping device moves to an open position.

[0022] In one or more embodiments, the supply step includes a conversion step of converting a sheet-like stock material into a damaged product having a lower density than the sheet-like stock material.

[0023] In one or more embodiments, the conversion step includes converting kraft paper into a cushioning damaged product.

[0024] In one or more embodiments, the control step includes depositing the damaged product into a receptacle at a selected packaging station.

Brief Description of the Drawings

[0025] [Figure 1] It is a front perspective view showing an exemplary packaging system. [Figure 2] It is an enlarged front perspective view of a part of the system of FIG. 1. [Figure 3] It is a cross-sectional view of an exemplary damage converter of the system of FIG. 1. [Figure 4] It is a rear perspective view of a damage carrier used in the system of FIG. 1. [Figure 5] It is a perspective view showing a part of the damage carrier of the system of FIG. 4 in an operable configuration. [Figure 6] It is a perspective view showing a part of the damage carrier of FIG. 4 in a cut-away configuration. [Figure 7] It is a rear perspective view showing a part of the system of FIG. 1. [Figure 8] It is a right side perspective view showing a part of the system of FIG. 7. [Figure 9] Figure 7 is a front perspective view showing a part of the system. [Figure 10] Figure 1 is a left side perspective view of the dunnage converter. [Figure 11] Figure 8 is a right-side perspective view of the system, showing an empty dunnage carrier approaching the guide surface. [Figure 12] Figure 11 is a left side perspective view of the system, showing the dunnage carrier in contact with the guide surface. [Figure 13] Figure 12 is a left side perspective view of the system, showing the dunnage carrier engaged with a guide surface further downstream than the guide surface position shown in Figure 12. [Figure 14] Figure 13 is a rear perspective view of the system. [Figure 15] Figure 10 is a right-side perspective view of the system, showing the dunnage carrier open and capturing the dunnage product. [Figure 16] Figure 10 is a left side perspective view of the system, showing the state in which the dunnage carrier has closed after passing the guide surface without any dunnage products. [Figure 17] Figure 10 is a left side perspective view of the system. [Figure 18] Figure 10 is a left side perspective view of the system, showing the dunnage carrier in the closed position to capture the dunnage product. [Figure 19] Figure 18 is a left side perspective view of the system, showing the dunnage carrier transporting the dunnage product from the dunnage converter. [Figure 20] This is a left-side perspective view showing a dunnage carrier transporting dunnage products to a packing station. [Figure 21] Figure 11 is a right-side perspective view of the system, showing the dunnage carrier approaching the guide surface while transporting the dunnage product. [Figure 22]Figure 15 is a right-side perspective view of the system, showing the dunnage carrier approaching the exit of the dunnage converter while transporting the dunnage product. [Figure 23] Figure 16 is a right-side perspective view of the system, showing the dunnage carrier bypassing the exit of the dunnage converter while transporting the dunnage product. [Figure 24] This is a right-side perspective view showing a dunnage carrier transporting dunnage products to a packing station. [Figure 25] This is an overhead perspective view of the packing station portion of the system shown in Figure 1. [Figure 26] Figure 25 is a front perspective view of the guide surface at the packing station. [Figure 27] Figure 26 is a front perspective view of the guide surface at the packing station, showing an empty dunnage carrier. [Figure 28] Figure 26 is a front perspective view of the guide surface of the packing station, showing the packing material carrier transporting the packed products to the packing station. [Figure 29] Figure 26 is a front perspective view of the guide surface of the packing station, showing the dunnage carrier transporting the dunnage products. [Figure 30] Figure 29 is another front perspective view of the guide surface of the packing station, showing the dunnage carrier transporting the dunnage products. [Figure 31] Figure 30 is an enlarged view of the dunnage carrier. [Figure 32] This is a front perspective view of an empty dunnage carrier in a closed state after passing through the guide surface shown in Figure 27. [Modes for carrying out the invention]

[0026] The present invention generally provides a packaging system and method for supplying dunnage products to a plurality of packaging stations. Referring in detail to the drawings, first with Figures 1 and 2, an exemplary packaging system 100 comprises a source 102 of dunnage products 104, a plurality of packaging stations 106, and a distribution assembly 110 that selectively distributes the dunnage products 104 from the source 102 to a predetermined packaging station 106. The distribution assembly 110 comprises one or more dunnage carriers 112 (Figure 4) configured to move along a closed distribution path and transport the dunnage products 104. The source 102 of dunnage products 104 and the packaging stations 106 are arranged along this distribution path.

[0027] The distribution assembly 110 further includes a plurality of control surfaces 114 located at the source 102 and each packing station 106, which cooperate with the dunnage carrier 112 to control the retrieval and placement of the dunnage products 104 as the dunnage carrier 112 moves along the distribution path. The system 100 may also include a controller 120 that selectively instructs the distribution assembly 110 to supply the dunnage products 104 to the packing stations 106, or instructs the source 102 to supply the dunnage products 104 for transport, or both.

[0028] The source 102 for the dunnage product 104 in the illustrated embodiment comprises a dunnage converter 122, which is a type of converter commonly called a cushioning converter. Conventional cushioning converters have been used to convert sheet-like stock materials, such as paper, into cushioning dunnage products or pads that are lower in density than the original sheet-like stock material. The exemplary stock material is kraft paper. The resulting pads are typically relatively lightweight and lower in density than the original stock material.

[0029] Figure 3 shows a cross-section of a typical dunnage converter 122. This dunnage converter 122 includes a forming assembly 124 into which sheet-like stock material is fed by a supply assembly 126. An example of sheet-like stock material is kraft paper, which is folded into a fan shape and supplied to the dunnage converter as a rectangular laminate. When the sheet-like stock material is drawn into the forming assembly 124, it is wrinkled and its side edges fold inward to form a cushioning strip 128 that is less dense than the sheet-like stock material. The supply assembly 126 typically joins or acts on the overlapping layers of the wrinkled stock material to fix them together in order to maintain the shape of the cushioning strip 128. A cutting assembly 130 downstream of the forming assembly 124 and the supply assembly 126 cuts dunnage products 104 of the desired length from the cushioning strip 128.

[0030] The illustrated dunnage converter 122 produces a dunnage product 104 having length, width, and thickness dimensions, wherein the length dimension is much larger than the width or thickness dimension. The dunnage converter discharges the dunnage product 104 in a generally horizontal discharge direction from the outlet 132 of the dunnage converter 122 along a first direction generally parallel to the length, where a shelf 134 presents and supports the dunnage product 104 for collection by one of the dunnage carriers 112 of the distribution assembly 110. The dunnage converter 122 is mounted on a frame or stand 136, and the dunnage product 104 is discharged from the source 102 at a height suitable for collection by the distribution assembly 110.

[0031] The source 102 for the dunnage product 104 is not limited to the use of paper dunnage or the type of cushioning pad described above. In other embodiments, different types of dunnage converters are used to produce other types of dunnage, including void fillers, cushioning materials, or bracing dunnage, each made from one or more airbags, foam-filled blocks or bags, paper strips, polystyrene granules, etc. The source 102 for the dunnage product 104 does not necessarily have to include a dunnage converter. For example, one or more dunnage converters may be remotely located, and the dunnage product 104 produced therein may be transported to the source 102. In this case, the source 102 comprises a dunnage product storage section and a dispenser that discharges the dunnage product 104 from an outlet for collection by a distribution assembly 110.

[0032] Returning to Figure 2, each packing station 106 includes a receptacle 140 for receiving cushioning pads and other dunnage products 104 received from the distribution assembly 110 for later use by packing workers. Each packing station 106 typically also includes, additionally or alternatively, a packing surface (not shown) for supporting a container in which packing workers place the dunnage products 104, or a container in which dunnage products are supplied directly without the intervention of packing workers. An exemplary packing surface may be provided by a table or conveyor belt. The receptacle 140 is typically positioned higher than the packing surface, and the distribution assembly 110 is positioned above the receptacle 140.

[0033] The illustrated receiving container 140 has one or more openings 142 toward one side of its bottom surface to facilitate the removal of the dunnage product 104 from the receiving container 140 by a packing worker. The receiving container 140 can be considered as part of either the distribution assembly 110 or the packing station 106.

[0034] The distribution assembly 110 distributes the dunnage products 104 supplied from the supply source 102 to the packing station 106. To achieve this purpose, the distribution assembly 110 may define a distribution path for the dunnage products 104 and include a conveyor 146 that transports the dunnage products 104 along this distribution path. The conveyor 146 transports one or more dunnage carriers 112 in a transport direction generally called the downstream direction. The upstream direction is the opposite of the downstream direction. In the illustrated embodiment, the conveyor 146 is an overhead conveyor, and the downstream direction is the direction of moving clockwise along the distribution path when viewed from above.

[0035] One or more dunnage carriers 112 are configured to move along a distribution path defined by a conveyor 146, to take dunnage products 104 from an outlet 132 of a supply source 102, and to transport and release the dunnage products 104 to one selected station among a plurality of packing stations 106. In the exemplary embodiments shown in Figures 4 to 6, each dunnage carrier 112 is connected to a segment of the conveyor 146 via a bracket 150 attached to the conveyor 146 and one or more magnetic elements 152 coupled to the dunnage carrier 112, allowing the dunnage carrier 112 to be easily removed from the conveyor 146 for adjustment, repair, or replacement. In the illustrated embodiment, two magnetic elements 152 are used, positioned perpendicular to each other. The magnets can be fixed to the conveyor, fixed to the bracket 150, or a combination thereof. In the illustrated embodiment, the flexible strap 153 also helps to secure the dunnage carrier 112 to the conveyor 146 as a backup for the magnetic element 152. Other fastening methods may be employed to secure the dunnage carrier 112 to the bracket 150 or the conveyor 146.

[0036] Each dunnage carrier 112 is equipped with a mechanism for removing dunnage products, such as the clamping device 154 shown in the figure. The clamping device 154, also called a gripper, is shaped like a pair of tongs. Thus, the clamping device 154 has a pair of arms, at least one of which rotates around a pivot axis 156. When mounted on the conveyor 146, the pivot axis 156 is oriented roughly parallel to the direction of movement of the conveyor, i.e., the downstream direction. The arms of the clamping device 154 include a pair of control units 160, like the handles or shafts of tongs, extending to one side of the pivot axis 156, and a pair of jaws 162 extending to the opposite side of the pivot axis 156. The control units 160 are used to control the operation of the clamping device 154, in particular the jaws 162. The pivot axis 156 allows the clamping device 154 to move between a closed position in which the distal ends of the jaws 162 are close together to hold the dunnage product 104, and an open position in which the distal ends of the jaws 162 are separated from each other, preparing to transport the dunnage product 104 to one of the packing stations 106 or to receive the dunnage product 104 at the outlet 132 of the supply source 102.

[0037] Therefore, the illustrated clamping device 154 engages and holds the dunnage product 104 between the distal ends of the jaws 162 using such a pinching motion. The jaws 162 may also be called arms, hands, or fingers, and their distal ends move closer to and further apart from each other to grip, hold, and release the dunnage product 104 between them. The distal ends of the jaws 162 may be provided with engaging surfaces that facilitate gripping the dunnage product 104, such as a specific surface texture or material, an element for perforating the dunnage product 104, an opening connected to a vacuum source for suction holding of the dunnage product 104, or other features that facilitate gripping the dunnage product 104.

[0038] In the illustrated clamping device 154, the distal ends of the jaws 162 are connected to each other by a flexible member 164 extending between the distal ends of the jaws 162. The flexible member 164 bends around a central portion 166 when the jaws 162 are in the closed position. This causes the jaws 162 and the flexible member 164 to form an opening that can receive and hold the dunage product 104 for transport. When the jaws 162 move to the open position, the flexible member 164 becomes straight, which allows the central portion 166 to easily discharge the dunage pad 104 from the clamping device 154 as the flexible member 164 becomes straight between the jaws 162.

[0039] The illustrated clamping device 154 is biased to the closed position by a biasing member 170, which is one or more springs or other elastic materials or structures. This allows the clamping device 154 to hold the dunnage product 104 without requiring active energy during transport. Energy is required only when moving the jaws 162 to the open position against the biasing member 170, and as will be described later, this energy is supplied by the movement of the conveyor 146. The clamping device 154 can also be biased to either the open or closed position using an alternative biasing member 170.

[0040] In the dunnage carrier 112, other types of clamping devices may be used instead of the illustrated clamping device 154. The dunnage carrier 112 may also have alternative means for receiving the dunnage products 104 at the outlet 132 of the supply source 102, holding the dunnage products for transport, and releasing or supplying the dunnage products 104 at the packing station 106. For example, smaller, more fluid dunnage products may be supplied to a carrier that the clamping device 154 transports along with the dunnage products on the conveyor 146.

[0041] Referring to Figures 7 through 23, the conveyor 146 not only transports the dunnage carrier 112 along the distribution path but also provides power to open the clamping device 154 against the action of the biasing member 170. In other words, the movement of the dunnage carrier 112 is used to open the clamping device 154 to take the dunnage product 104 from the outlet 132 of the supply source 102, and to open the clamping device 154 to place the dunnage product 104 at the selected packing station 106. To achieve the opening of the clamping device 154, the distribution assembly 110 is positioned adjacent to the conveyor 146 at each packing station 106 and utilizes a control surface 114 positioned adjacent to the outlet 132 of the supply source 102. The control unit 160 of the clamping device 154 is configured to engage with the control surface 114 and move along the control surface 114 as the conveyor 146 advances the dunnage carrier 112. For this purpose, a bearing or rotating bushing, including a bushing made of a low-friction material, may be attached to the distal end of the control unit 160. The interaction between the control unit 160 and the control surface 114 controls the clamping device 154 to move between an open position (Figure 15) and a closed position (Figure 12). The control surface 114 functions as a cam, defining a path also called a cam path, and the control unit 160 functions as a cam follower to achieve the desired pivoting motion of the jaws 162. By using the control surface 114, each dunnage carrier 112 does not require an active power mechanism to open and close the clamping device 154 when it moves between the open and closed positions.

[0042] Each control surface 114 provides multiple paths to the control unit 160 of the clamping device 154, depending on whether the clamping device 154 needs to be in an open or closed position. These paths may be defined by grooves, recesses, or projections that receive or engage with the distal end of the control unit 160 of the clamping device 154 as the conveyor 146 moves the dunnage carrier 112 near the control surface 114. These paths are also called cam paths or cam trajectories. In the illustrated embodiment, each control surface 114 has three paths, which approach or branch off from each other to move the distal end of the control unit 160 apart or closer together, thereby moving the jaws 162 between a closed position and an open position.

[0043] Bypass arms 176 are mounted in front of each control surface 114, adjacent to the conveyor 146, to control which path the control unit 160 takes on the control surface 114. The bypass arms 176 are positioned to engage with the dunnage products 104 held by the jaws 162 as the dunnage carrier 112 passes over them. The bypass arms 176 change the orientation of the clamping device 154 through engagement with the dunnage products 104. The bypass arms 176 are also called dunnage influencers or dunnage deflectors. The bypass arms 176 are positioned in front of the control surface 114, i.e., upstream of the control surface 114, so that the dunnage carrier 112 passes the bypass arms 176 before the control surface 114.

[0044] In the illustrated embodiment, the control surface 114 is mounted on the inside of the conveyor 146, and the bypass arm 176 is mounted on the outside of the conveyor 146. The inside of the conveyor 146 is the inside of the closed distribution path defined by the conveyor 146, and the outside of the conveyor 146 is the opposite side, i.e., the outside of the closed distribution path defined by the conveyor 146. The bypass arm 176 interacts with the dunnage product 104 held by the clamping device 154, causing the clamping device 154 to rotate around the pivot axis 156, guiding the control unit 160 of the clamping device 154 to engage with the control surface 114, and the control unit 160 and the control surface 114 move the clamping device 154 to a predetermined position.

[0045] When the dunnage carrier 112 approaches the supply source 102 while holding the dunnage product 104, the clamping device 154 needs to maintain its closed position. The clamping device 154 does not need to open (move to the open position) to release the dunnage product 104 at the supply source 102. Nor does the clamping device 154 need to move to the open position to receive the dunnage product 104 from the supply source 102. Therefore, the bypass arm 176 guides the dunnage carrier 112 past the supply source 102 while holding the dunnage product 104 and keeping the clamping device 154 in the closed position (see Figures 21 to 23). As the dunnage carrier 112 passes the bypass arm 176, the bypass arm 176 engages with the dunnage product 104. This causes the clamping device 154 to rotate around the pivot axis 156, guiding both control units 160 to a common bypass path on the control surface 114. In the illustrated embodiment, the bypass path is the uppermost path. This bypass path keeps the clamping device 154 closed while the dunnage carrier 112 passes through the outlet 132 of the supply source 102.

[0046] This rotational position of the clamping device 154 positions the control unit 160 vertically above the jaws 162 so that the dunnage product 104 held by the jaws 162 passes below the shelf 134 at the outlet 132 of the supply source 102. When the control unit 160 moves away from the control surface 114, the control surface 114 can guide or allow the control unit 160 to rotate the clamping device 154 from the rotational position and position the control unit 160 in a nearly horizontal, non-rotating default position or transport position as the dunnage carrier 112 transports the dunnage product 104 to the selected packing station 106.

[0047] When the dunnage carrier 112 approaches the supply source 102, if it is empty and does not hold the dunnage product 104, the clamping device 154 needs to be in the open position to retrieve the dunnage product 104 from the supply source 102. The dunnage carrier 112 passes the bypass arm 176 without the bypass arm 176 rotating the clamping device 154 into a rotational position. The bypass arm 176 is positioned to engage with the dunnage product 104 held in the jaws 162 of the clamping device 154, or with the upper jaw 162 of the clamping device 154 raised by the presence of the dunnage product 104 between the upper and lower jaws 162. Therefore, if the dunnage product 104 is not present, the dunnage carrier 112 is not affected by the bypass arm 176.

[0048] The illustrated clamping device 154 comprises two control units 160, namely a first control unit or first cam follower 190 and a second control unit or second cam follower 192. When the system 100 opens the jaws 162 (moves the jaws 162 of the clamping device 154 to the open position), the control unit 160 engages with the control surface 114, which then branches the control units 190 and 192, leading them to different paths. The first control unit 190 (lower control unit) moves along a path that is generally parallel to the direction of movement, the downstream direction. In the illustrated embodiment, this path is substantially horizontal. The second control unit 192, the upper control unit, has its distal end positioned away from the distal end of the first control unit 190 and engages with the control surface 114 so that the second control unit 192 follows another path. This path is typically located between the horizontal path and the uppermost path (bypass path) and is therefore called the intermediate path. The paths of the first control unit 190 and the second control unit 192 branch vertically, causing at least one jaw 162 of the clamping device 154 to rotate around the pivot axis 156 and move the clamping device 154 to the open position.

[0049] In the open position, the clamping device 154 is ready to receive the dunnage product 104 from the outlet 132 of the supply source 102. As the dunnage carrier 112 passes through the outlet 132 of the supply source 102, the control surface 114 reconnects the paths of the control units 190 and 192, and the flexible member 164 closes the jaws 162 again to capture the dunnage product 104 (if any) on the shelf 134 at the outlet 132 of the supply source 102. In the illustrated embodiment, the intermediate path abruptly ends, and the biasing member 170 quickly returns the jaws 162 of the clamping device 154 to the closed position, capturing the dunnage product 104 between the jaws 162 of the clamping device 154.

[0050] In the illustrated embodiment, the control surface 114 of the supply source 102 is positioned on the curved portion of the conveyor 146 and follows the curved path of the conveyor 146. In other words, the control surface 114 is parallel to the distribution path defined by the conveyor 146. If the conveyor 146 adjacent to the supply source 102 is straight, then the control surface 114 is also straight. In the illustrated configuration, the vertical displacement of the path defined by the control surface 114 is used to move the clamping device 154 from a closed position to an open position. The curvature of the control surface 114 along the path of the conveyor 146 does not affect whether the clamping device 154 is in the open or closed position. The control surface is also curved with respect to the pivot axis 156, so that the control unit 160 can engage without interfering with the various paths of the control surface. The distance between the control surface 114 and the pivot axis 156 is generally determined based on the length of the control unit 160 extending from the pivot axis 156. By combining the features of the control surface 114 with the use of different lengths for the first control unit 190 and the second control unit 192, it is possible to appropriately guide or direct either the first control unit 190 or the second control unit 192 to a desired path.

[0051] Referring to Figures 21 to 32, the conveyor 146 and the dunnage carrier 112 transport the dunnage product 104 to one of the selected packing stations 106. Operating similarly to the control surface 114 of the supply source 102, at the control surface 114 adjacent to each packing station 106, the first control unit 190 and the second control unit 192 are guided to branching paths that branch vertically to open the jaws 162. However, at the selected packing station 106, the clamping device 154 moves to the open position to release the dunnage product 104 and supply the dunnage product 104 to the packing station 106. In the illustrated embodiment, once the clamping device 154 moves to the open position and separates the jaws 162, the dunnage product 104 falls into the receiver 140. In other words, gravity transports the dunnage product 104 from the dunnage carrier 112 to the packing station 106.

[0052] The control surfaces 114 of each packing station 106 have slightly different configurations because their functions differ from those of the control surface 114 of the supply source 102. If the clamping device 154 is opened in a generally horizontal transport position, the dunnage product 104 can be successfully received and captured at the outlet 132 of the supply source 102, and it is also possible that the dunnage product 104 could fall from the clamping device 154 into the receiver 140 of the packing station 106. However, by rotating the clamping device 154 and opening the jaws 162 downwards, the dunnage product 104 can be reliably transported to the packing station 106. In other words, the system 100 can use the bypass arm 176 and the control surface 114 to control not only whether the clamping device 154 is in the open or closed position, but also its direction of rotation.

[0053] At each packing station 106, the bypass arm 176 is normally controlled by the controller 120, which controls the actuator to move the bypass arm 176 between an extended transport position and a retracted bypass position. In contrast to the control surface 114 of the supply source 102, when no dunnage product 104 is supplied to the packing station 106, the bypass arm 176 retracts to avoid interfering with the dunnage product 104. In this case, the control unit 160 passes both control surfaces 114 along the common bypass path, and the clamping device 154 remains in the closed position without changing orientation. The bypass path of the control surface 114 at the packing station 106 is horizontal and parallel to the distribution path and the conveyor 146.

[0054] However, when transporting the dunnage product 104 to the packing station 106, the controller 120 moves the bypass arm 176 to an extended transport position. This is achieved by an actuator 196, which is a solenoid, pneumatic motor, electric motor, or other drive device. When the clamping device 154 holds the dunnage product 104, the dunnage product 104 engages with the bypass arm 176, causing the clamping device 154 to rotate around the pivot axis 156 into a rotational position. In the rotational position, the control units 160 of the clamping device 154, specifically the first control unit 190 and the second control unit 192, engage with branched paths on the control surface 114 of the packing station 106, respectively. There are usually only two paths on the control surface 114 of the packing station 106: the bypass path described above and a control path that branches off from the bypass path. A funnel or other guide structure guides the second control unit 192 to a branched path that branches vertically from the bypass path followed by the first control unit 190. As the first control unit 190 and the second control unit 192 separate vertically along their respective paths, the jaws 162 of the clamping device 154 move to the open position, releasing the dunnage product 104. In the rotated position, the openings of the jaws 162 of the clamping device 154 face downwards from the horizontal, and gravity pulls the dunnage product 104 out of the clamping device 154, causing it to fall into the receiving container 140, where it is supplied to the packing station 106.

[0055] If the bypass arm 176 is in the extended transport position but the clamping device 154 is not holding the dunnage product 104, or if the bypass arm 176 is in the retracted bypass position, the dunnage carrier 112 passes the bypass arm 176 without changing direction, and both control units 190 and 192 cross the bypass path. Therefore, the controller 120 controls the bypass arm 176 at each packing station 106, allowing the dunnage product 104 to be transported to a subsequent packing station 106 by bypassing one or more packing stations 106. On the other hand, since the supply source 102 is bypassed only when the dunnage carrier 112 is transporting the dunnage product 104, the bypass arm 176 adjacent to the control surface 114 on the supply source 102 side can remain in the extended position.

[0056] Each packing station 106 may be equipped with a sensor 200 that detects the filling status of an adjacent receiver 140. The sensor 200 outputs a signal to the controller 120. Based on the signal from the sensor 200, the controller 120 can move the bypass arm 176 corresponding to the packing station 106 to the extended position, thereby "requesting" the supply of the next dunnage product 104 being transported by the dunnage carrier 112 to the packing station 106. To prevent a shortage of dunnage product 104 at packing stations 106 located on distribution paths far from the supply source 102, the controller 120 can control the bypass arm 176 of each packing station 106 to ensure that the dunnage product 104 is evenly distributed to the packing stations 106. Thus, alternative control methods are also envisioned, in which the controller 120 can control each bypass arm 176 so that the dunnage carrier 112 can bypass one or more packing stations 106 without delivering the dunnage product 104. For example, the system can supply the dunnage product 104 to the packing station 106 with the least amount of dunnage product 104 in the receiver 140, or to the packing station 106 that is consuming the dunnage product 104 the fastest. The signal from the sensor 200 may indicate that the receiver 140 at a particular packing station 106 is less than full or empty and requires dunnage product 104. Alternatively, the signal from the sensor 200 may only indicate the degree of filling of the receiver 140, or whether the receiver 140 is sufficiently filled to detect the dunnage product 104.

[0057] The controller 120 (Schematically shown in Figure 1) selectively directs the components of the distribution assembly 110 to distribute the dunnage product 104 to each packing station 106. The controller 120 can control the supply source 102 to supply the dunnage product 104 to the distribution assembly 110 and control the distribution assembly 110 to supply the dunnage product 104 to each packing station 106. The supply source 102 can also operate independently of the controller 120 and continuously supply the dunnage product 104 to the outlet 132 as soon as the previously supplied dunnage product 104 is removed. The controller 120 normally operates without operation by packing workers, but by providing input / output devices such as a keyboard and display, packing workers can be provided with means to access information from or input information to the controller 120. As another example, instead of a sensor informing the controller that any of the receivers 140 needs additional dunnage product 104, a packing worker could use a foot pedal or other switch to signal the controller 120 that the packing station 106 needs more dunnage product 104, and the controller 120 could then control the required supply. In this way, the controller 120 facilitates the automation of most of the packing system 100.

[0058] The controller 120 is an electronic device or system that manages and controls the operation of other devices in the packaging system 100, such as the conveyor 146, the bypass arm 176, and the supply source 102. The controller 120 may comprise components such as a microprocessor, memory, one or more input / output interfaces, circuitry, and software. A computer with a central processing unit, memory, and dedicated software can function as the controller 120 that controls the operating elements of the packaging system 100.

[0059] In summary, the supply source 102 supplies the first dunnage product 104 at the outlet 132. For example, a dunnage converter can convert stock material into dunnage products supported on shelves 134 at the outlet 132. The conveyor 146 moves the empty dunnage carrier 112 along the distribution path to the supply source 102. As the dunnage carrier 112 approaches the supply source 102, the control unit 160 of the clamping device 154 engages with the control surface 114 adjacent to the supply source 102, and the first control unit 190 and the second control unit 192 move away from each other as they move along separate paths defined by the control surface 114, moving the clamping device 154 to the open position. As the dunnage carrier 112 moves along the control surface 114 and passes the outlet 132 of the supply source 102, the control surface path brings the control units 190 and 192 closer again, the clamping device 154 returns to the closed position, and the dunnage product 104 is captured on the shelf 134 at the outlet 132 of the supply source 102 and transported from the outlet 132 along the distribution path. The controller 120 controls the bypass arm 176 to transport the dunnage product to the selected packing station 106. At the packing station 106 to be bypassed, the bypass arm 176 retracts, and the conveyor 146 allows the dunnage carrier 112 to pass through the packing station 106 without changing its orientation.

[0060] When the dunnage carrier 112 reaches the selected packing station 106, the extended bypass arm 176 engages with the dunnage product 104, rotating the clamping device 154 around the pivot axis 156, causing the jaws 162 and the dunnage product 104 to rotate downward. The control unit 160 of the clamping device 154 engages with the control surface 114 adjacent to the selected packing station 106, guiding the first control unit 190 and the second control unit 192 to a branching path. This branching path opens the jaws 162, moving the clamping device 154 to the open position, dropping the dunnage product 104 from the clamping device 154 and transporting the dunnage product 104 to the packing station 106. The dunnage product 104 falls into the receiving container 140, and when the packing worker is ready, they pull the dunnage product 104 out of the opening 142 of the receiving container and use it to pack one or more items in a shipping container. The conveyor 146 continues to move the dunnage carrier 112 along the distribution path, returning it to the supply source 102 to collect another dunnage product 104 and continue processing.

[0061] As can be understood from the foregoing, an exemplary method of supplying a dunnage product from a source to a plurality of packing stations includes: (i) supplying the dunnage product from the outlet of the source; (ii) moving a dunnage carrier along a distribution path passing through the outlet of the source and the plurality of packing stations; (iii) controlling the dunnage carrier to move between an open position and a closed position through the interaction of the dunnage carrier with control surfaces installed adjacent to each of the source and the plurality of packing stations along the distribution path; and (iv) moving the dunnage carrier to an open position or a closed position at each of the source and the plurality of packing stations by selectively controlling the path defined by the control surfaces with a control arm associated with the dunnage carrier.

[0062] In summary, the exemplary packaging system 100 and method supply dunnage product 104 from a source 102 to a distribution assembly 110 for distribution to one of a selection of a plurality of packaging stations 106. The distribution assembly 110 comprises a closed distribution path, at least one dunnage carrier 112 configured to transport the dunnage product 104 along the distribution path, a plurality of control surfaces 114, and a dunnage deflector or bypass arm 176 positioned at each packaging station 106. Each control surface 114 has a plurality of cam paths. The dunnage carrier 112 comprises at least one cam follower or control unit 160 configured to engage with a selected cam path on the control surface 114. The dunnage deflector 176 is also selectively operable to engage with the dunnage product 104 in the dunnage carrier 112 and guide the cam follower 160 to a selected cam path to transport the dunnage product 104 to a selected packaging station 106.

[0063] While the present invention has been shown and described in relation to specific embodiments, those skilled in the art will be able to conceive of equivalent changes and modifications by reading and understanding this specification and the accompanying drawings. In particular, with respect to the various functions performed by the components described above (parts, assemblies, devices, compositions, etc.), the terms used to describe such components (including references to “means”) are intended, unless otherwise stated, to correspond to any component that performs a particular function of the described component (i.e., is functionally equivalent), even if it is not structurally equivalent to the disclosed structure that performs the function in the exemplary embodiments of the present invention described herein.

Claims

1. At least one source of Dunage products, Multiple packing stations, A distribution assembly that selectively distributes the dunnage product from the supply source to one of the selected packing stations, The distribution assembly comprises a closed distribution path, at least one dunnage carrier configured to transport the dunnage product along the distribution path, a plurality of control surfaces, and dunnage deflectors provided at the supply source and each of the packing stations, Each of the control surfaces has a plurality of cam paths, and one of the control surfaces is located adjacent to the supply source and each of the packing stations. The dunnage carrier comprises at least one cam follower configured to engage with one of the selected cam paths, A packaging system in which the dunnage deflector at each packaging station is selectively operable to selectively engage with the dunnage product in the dunnage carrier, guide the cam follower of the dunnage carrier to a selected cam path, and transport the dunnage product to a selected packaging station.

2. The system according to claim 1, further comprising a controller for selectively controlling the dunnage deflectors of each packing station and distributing the dunnage product to one selected packing station.

3. The system according to claim 1 or 2, wherein the distribution assembly comprises a conveyor capable of defining the distribution path and transporting the at least one dunnage carrier along the distribution path.

4. The system according to any one of claims 1 to 3, wherein the distribution path is located above the packing station.

5. The system according to any one of claims 1 to 4, wherein the dunnage deflector of each packing station is selectively movable between an extended position that engages with the dunnage product in the dunnage carrier and a retracted position away from the extended position.

6. The system according to any one of claims 1 to 5, wherein the source of the dunnage product comprises a converter that converts a sheet-like stock material into a dunnage product with a lower density than the sheet-like stock material.

7. The system according to claim 6, wherein the converter is a cushioning converter capable of converting kraft paper into a cushioning dunnage product.

8. The system according to claim 6, wherein the converter is installed at a high position by a stand.

9. The system according to any one of claims 1 to 8, wherein at least one of the packing stations comprises a receptacle for receiving and storing dunnage products until needed.

10. The system according to any one of claims 1 to 9, wherein each packing station is equipped with a receptacle for receiving and storing the dunnage products until needed.

11. The system according to claim 10, wherein the receiver has an opening on a side surface near the bottom of the receiver in order to facilitate the removal of the dunage products in the order they were supplied.

12. A supply step of supplying the dunnage product from the supply source, A transport step of transporting the dunnage product from the supply source along the distribution route, which has a plurality of packing stations arranged along the distribution route, via a distribution assembly, A control step of controlling the components of the distribution assembly and transporting the dunnage product to one selected from a plurality of packing stations, Packaging methods including those mentioned.

13. The packaging method according to claim 12, wherein the transport step includes transporting the dunage product with a clamping device attached to a conveyor.

14. The packaging method according to claim 12 or 13, wherein the transport step includes automatically opening a pair of jaws of the clamping device to accept the dunnage product when the conveyor moves the clamping device through the outlet of the supply source, and automatically closing the clamping device to capture the dunnage product between the pair of jaws when the conveyor moves the clamping device through the supply source.

15. The packaging method according to any one of claims 12 to 14, wherein the control step includes automatically opening the clamping device when the conveyor moves the clamping device through the selected packaging station.

16. The packaging method according to any one of claims 13 to 15, wherein the control step controls a dunnage deflector adjacent to each of the plurality of packaging stations to move between an extended position and a retracted position in order to control the orientation of the dunnage product as the dunnage product is transported through each of the packaging stations.

17. The packaging method according to any one of claims 13 to 16, wherein the control step includes controlling a dunnage deflector adjacent to each of the plurality of packaging stations to move between an extended position and a retracted position in order to control the orientation of the dunnage product and the clamping device as the dunnage product passes through each of the packaging stations, and the clamping device comprises a cam follower that interacts with a cam path on a cam surface at each of the packaging stations, which controls whether or not the clamping device moves to an open position.

18. The packaging method according to any one of claims 12 to 17, wherein the supply step includes a conversion step of converting a sheet-like stock material into a dunnage product with a lower density than the sheet-like stock material.

19. The packaging method according to claim 18, wherein the conversion step includes converting kraft paper into a cushioning dunnage product.

20. The packaging method according to any one of claims 12 to 19, wherein the control step includes placing the dunnage product into a receiver at the selected packaging station.

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