Dunnage system with automated feed capability

Abstract

A dunnage conversion machine includes a drive member configured to deform a feedstock material into a continuous length of dunnage. The machine also includes a cutting device configured to cut a dunnage sheet from a continuous length of dunnage. The cutting device includes a clamp configured to move to a closed position in which the clamp exerts a force on the dunnage sheet to hold the dunnage sheet on the machine until the dunnage sheet is pulled away from the machine, at which time the clamp moves to an open position, and the machine advances a continuous length of dunnage to initiate another cutting cycle.

Description

Technical Field

[0001] The present disclosure relates to systems for converting paper stock and other materials into dunnage for use as packaging material. Background Art

[0002] Paper-based protective packaging or padding is produced by creased or otherwise deformed paper stock. More specifically, paper padding is produced by passing a substantially continuous paper strip through a padding conversion machine. The continuous paper strip can be provided by, for example, a paper roll or a fan-folded stack of paper. The padding conversion machine, for example, uses opposing rollers to convert the stock material into a lower density padding material, which passes between the opposing rollers. The rollers clamp and pull the stock material from the roll or stack and deform the stock material when the stock material passes between the rollers. The resulting padding can be cut into a desired length to effectively fill the void space in the container holding the product. Individual padding material sheets can be produced as needed for an operator or automated apparatus performing a packaging operation, typically immediately after cutting, by an operator or apparatus to grasp or otherwise manipulate individual padding material sheets. When needed during a packaging operation, an operator or automated apparatus typically commands the production of each padding sheet. Summary of the invention

[0003] In one aspect of the disclosed technology, a dunnage conversion machine includes a drive member configured to deform stock material into a continuous length of dunnage and a cutting mechanism. The cutting mechanism includes a cutting device configured to cut dunnage sheets from the continuous length of dunnage and a clamp configured to exert a force on the dunnage sheet to hold the dunnage sheet on the dunnage conversion machine.

[0004] In another aspect of the disclosed technology, the drive member includes one or more rollers.

[0005] In another aspect of the disclosed technology, a cutting device includes a blade.

[0006] In another aspect of the disclosed technology, the clamp is further configured to move between a first position and a second position, where the clamp exerts a force on the gasket piece in the first position.

[0007] In another aspect of the disclosed technology, the clamp is further configured such that the clamp does not hold the gasket sheet when the clamp is in the second position.

[0008] In another aspect of the disclosed technology, the dunnage conversion machine further includes a controller. The cutting mechanism further includes a sensor and a drive mechanism, the sensor being communicatively coupled to the controller and configured to detect the presence of the dunnage piece using a sensing field of the sensor, and the drive mechanism being communicatively coupled to the controller and configured to move the clamp between the first position and the second position of the clamp.

[0009] The controller is configured to generate an output when the spacer piece is removed from the sensing field of the sensor. The output, when received by the drive mechanism, causes the drive mechanism to move the clamp from the first position to the second position.

[0010] In another aspect of the disclosed technology, the clamp is further configured to hold the dunnage piece against an adjacent surface of the dunnage conversion machine with sufficient compression to prevent the dunnage piece from falling from the dunnage conversion machine.

[0011] In another aspect of the disclosed technology, the dunnage conversion machine further includes a housing configured to support the cutting device. The clamp is further configured to hold the cut dunnage piece against the housing.

[0012] In another aspect of the disclosed technology, the clamp is further configured to hold the dunnage sheet against an adjacent surface of the dunnage conversion machine with sufficient compression to retain the dunnage sheet on the dunnage conversion machine until the dunnage sheet is pulled from the dunnage conversion machine.

[0013] In another aspect of the disclosed technology, the cutting mechanism further includes a bumper mounted on the clamp and configured to contact and hold the gasket sheet when the clamp is in the first position.

[0014] In another aspect of the disclosed technology, the drive mechanism further includes at least one roller configured to feed the continuous length of the dunnage sheet to the cutting mechanism in a first direction. The drive mechanism is further configured to reverse the rotation direction of the at least one roller when the clamp is in the first position in response to input from the controller, so that the drive mechanism pulls the continuous length of dunnage in a second direction opposite to the first direction, so that the cutting device cuts the dunnage sheet from the continuous length of dunnage.

[0015] In another aspect of the disclosed technology, the clamp is further configured such that when the drive mechanism pulls the continuous length of dunnage in the second direction, a force applied by the clamp prevents the continuous length of dunnage from moving in the second direction.

[0016] In another aspect of the disclosed technology, the cutting device is a blade, and the clamp is further configured to wrap the continuous length of pad material around the blade when the clamp is in the first position.

[0017] In another aspect of the disclosed technology, an outer surface of the bumper includes an adhesive material.

[0018] In another aspect of the disclosed technology, the bumper includes an elastomeric material.

[0019] In another aspect of the disclosed technology, the output generated by the controller when the spacer piece is removed from the sensing field of the sensor is a first output, and the controller is further configured to generate a second output when the sensor detects that the spacer piece is within the sensing field of the sensor. The second output, when received by the drive mechanism, causes the drive mechanism to maintain the clamp in the first position.

[0020] In another aspect of the disclosed technology, a clamp is configured to retain the severed gasket piece at a location downstream of the blade in the cutting assembly.

[0021] In another aspect of the disclosed technology, a system for producing dunnage includes a dunnage conversion machine having a drive member configured to deform a stock material into dunnage and a feed port configured to feed the stock material into the dunnage conversion machine. The feed port includes an entry chute connected to the dunnage conversion machine and a protrusion connected to the entry chute. The protrusion includes a plurality of surface portions configured to bend the stock material as the stock material passes over the surface portion.

[0022] In another aspect of the disclosed technology, a protrusion extends downwardly from an inlet end of the inlet chute.

[0023] In another aspect of the disclosed technology, a protrusion includes a planar surface having a plurality of surface portions.

[0024] In another aspect of the disclosed technology, the plurality of surface portions further includes a substantially planar upper surface portion, an outwardly curved intermediate surface portion adjacent the upper surface portion, and a substantially planar lower surface portion adjacent the intermediate surface portion.

[0025] In another aspect of the disclosed technology, the upper surface portion is angled upward in the direction of travel of the feedstock material into the feed opening, and the lower surface portion is angled downward in the direction of travel of the feedstock material into the feed opening.

[0026] In another aspect of the disclosed technology, the upper surface portion is a first upper surface portion, the intermediate surface portion is a first intermediate surface portion, and the intermediate surface portion is a first lower surface portion.

[0027] The plurality of surface portions further comprises a second upper surface portion adjacent to the first upper surface portion. The first upper surface portion and the second upper surface portion are symmetrically arranged about a transverse centerline of the protrusion. The plurality of surface portions further comprises a second intermediate surface portion adjacent to the first intermediate surface portion. The first intermediate surface portion and the second intermediate surface portion are symmetrically arranged about a transverse centerline of the protrusion.

[0028] The plurality of surface portions further includes a second lower surface portion adjacent to the first lower surface portion. The first lower surface portion and the second lower surface portion are symmetrically arranged about a transverse centerline of the protrusion.

[0029] In another aspect of the disclosed technology, the plurality of surface portions further include a first upper end portion and a second upper end portion, each of the first upper end portion and the second upper end portion having a curved profile. The first upper end portion abuts the first side of the protrusion and the first upper surface portion, and the second upper end portion abuts the second side of the protrusion and the second upper surface portion.

[0030] The plurality of surface portions further comprises a first intermediate end portion and a second intermediate end portion, each of the first intermediate end portion and the second intermediate end portion having a curved profile. The first intermediate end portion abuts the first side and the first intermediate surface portion. The second intermediate end portion abuts the second side and the second intermediate surface portion.

[0031] The plurality of surface portions further comprises a first lower end portion and a second lower end portion, each of the first lower end portion and the second lower end portion having a curved profile. The first lower end portion abuts the first side and the first lower surface portion. The second lower end portion abuts the second side and the second lower surface portion.

[0032] In another aspect of the disclosed technology, a dunnage conversion machine includes one or more rollers. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The following drawings illustrate specific embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not drawn to scale and are intended to be used in conjunction with the explanations in the following detailed description. The embodiments of the present disclosure will be described below in conjunction with the drawings, wherein the same reference numerals represent the same elements.

[0034] Figure 1 is a front perspective view of a system for producing dunnage depicting a clamp of the system in an open position.

[0035] Figure 2 yes Figure 1 A side view of the system shown in , depicting the clamp in a closed position.

[0036] Figure 3 yes Figure 1 and Figure 2 A side view of the system shown in , depicting the clamp in the open position.

[0037] Figure 4 It passes through Figure 7 The line IV-IV intercepts Figures 1 to 3 A cross-sectional view of the system shown in FIG. 1 and depicting the clamp in a closed position.

[0038] Figure 5 It passes through Figure 7 The line IV-IV intercepts Figures 1 to 4 A cross-sectional view of the system shown in FIG. 1 and depicting the clamp in an open position.

[0039] Figure 6 yes Figures 1 to 5 A top front perspective view of the system shown in , with a first side wall of a housing of the system removed for clarity of illustration.

[0040] Figure 7 yes Figures 1 to 6 Top view of the system shown in .

[0041] Figure 8 yes Figures 1 to 7 A side view of the system shown in , depicting the cover of the system in a closed position.

[0042] Fig. 9 yes Figures 1 to 8 A side view of the system shown in , depicting the hood in an open position.

[0043] Fig.10 yes Figures 1 to 9 A top rear perspective view of the system shown in , depicting the clamp in a closed position.

[0044] Fig.11 yes Figures 1 to 10 A top rear perspective view of the system shown in , depicting the clamp in the open position.

[0045] Fig.12 It passes through Figure 7 The line "IV-IV" is intercepted Figures 1 to 11 A cross-sectional view of the system shown in FIG. 1 and depicting the clamp in a closed position.

[0046] Fig.13 It passes through Figure 7 The line "IV-IV" is intercepted Figures 1 to 12 A cross-sectional view of the system shown in FIG. 1 and depicting the clamp in an open position.

[0047] Fig.14 yes Figures 1 to 13 0014] A side view of a dunnage conversion machine of the system shown in FIG. 1 with the side walls of the dunnage conversion machine removed for clarity of illustration and depicting the clamp in a closed position.

[0048] Fig.15 yes Fig.14 A side view of a dunnage conversion machine shown in FIG. 1 with the side walls removed and depicting the clamp in an open position.

[0049] Fig.16 It passes through Figure 7 The line XVI-XVI intercepts Fig.14 and Fig.15 A cross-sectional view of a dunnage conversion machine is shown in FIG. 1 and depicts the clamp in a closed position.

[0050] Fig.17 It passes through Figure 7 The line XVI-XVI intercepts Figures 14 to 16 A cross-sectional view of a dunnage conversion machine is shown in FIG. 1 and depicts the clamp in an open position.

[0051] Fig.18 yes Figures 1 to 17 A front perspective view of the system shown in FIG. 1 depicts the clamp in a closed position.

[0052] Fig.19 It passes through Figure 7 The line "IV-IV" is intercepted Figures 1 to 18 A cross-sectional view of a system shown in FIG. 1 and depicting the conversion of feedstock material into dunnage before the dunnage has been cut.

[0053] Fig. 20 It passes through Figure 7 The line "IV-IV" is intercepted Figures 1 to 19 A cross-sectional view of the system shown in , depicting a sheet of raw material held by a clamp after cutting.

[0054] Fig.21 After the raw material sheet is removed from the dunnage conversion machine, it passes through Figure 7 The line "IV-IV" is intercepted Figures 1 to 20 A cross-sectional view of the system shown in FIG.

[0055] FIG. 22A to FIG. 22D yes Figures 1 to 21 A perspective view of a system shown in FIG. 1 , which is configured to hold a single stack of fan-folded feedstock material.

[0056] FIG. 23A to FIG. 23D yes Figures 1 to 22D A perspective view of a system shown in FIG. 1 , which is configured to hold multiple stacks of fan-folded feedstock material.

[0057] FIG. 24A to FIG. 24D yes Figure 1 to Figure 23D A perspective view of a system shown in , the system being configured to hold a single stack of fan-folded stock material and wherein a top sheet of a top stack is folded upon itself.

[0058] FIG. 25A to FIG. 25D yes Figures 1 to 24D A perspective view of a system shown in , the system being configured to hold multiple stacks of fan-folded stock material and wherein a top sheet of a top stack is folded upon itself. DETAILED DESCRIPTION

[0059] The following discussion omits or only briefly describes conventional features of the disclosed technology that are obvious to those skilled in the art. Reference to various embodiments does not limit the scope of the claims appended hereto. Additionally, any examples set forth in this specification are not intended to be limiting, but merely set forth some of the many possible embodiments of the appended claims. Further, the specific features described herein may be used in combination with other descriptive features in each of the various possible combinations and arrangements. One of ordinary skill in the art will know how to use the present invention in conjunction with routine experiments to achieve other results not specifically disclosed in the examples or embodiments.

[0060] Unless otherwise specifically defined herein, all terms will be given their broadest possible interpretation, including the meaning implied from the specification and the meaning understood by those skilled in the art and / or as defined in dictionaries, papers, etc. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art in the disclosed technical field. It must also be noted that, unless otherwise stated, as used in the specification and the appended claims, the singular forms "a", "an" and "the" include plural referents, and the terms "including" and / or "comprising" when used in this specification specify the presence of the described features, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or groups thereof. Additionally, methods, apparatuses and materials similar or equivalent to the methods, apparatuses and materials described herein can also be used in the practice or testing of the disclosed technology.

[0061] Various examples of the disclosed technology are provided throughout this disclosure. The use of these examples is illustrative only and in no way limits the scope and meaning of the present invention or any illustrative form. Likewise, the present invention is not limited to any particular preferred embodiment described herein. In fact, after reading this specification, modifications and variations of the present invention will be apparent to those skilled in the art and may be made without departing from its spirit and scope. Therefore, the present invention is limited only by the terms of the claims and the full scope of equivalents authorized by the claims.

[0062] The terms "substantially" or "substantially equal" are used herein to describe certain relationships between features of suppressors. As used herein, the terms "substantially" and "substantially equal" indicate that the equal relationship is not a strict relationship, and functionally similar changes are not excluded. Unless otherwise indicated by the context or description, the use of the terms "substantially" or "substantially equal" in conjunction with two or more described dimensions to indicate that the equal relationship between the dimensions includes changes that do not change the least significant digits of the dimensions using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.). As used herein, the term "substantially parallel" indicates that the parallel relationship is not a strict relationship, and functionally similar changes are not excluded. As used herein, the term "substantially orthogonal" indicates that the orthogonal relationship is not a strict relationship, and functionally similar changes are not excluded.

[0063] A system for converting a high density stock material into a low density padding is disclosed. The stock material is processed by a longitudinal crimper that forms crimps longitudinally in the stock material to form the padding or by a transverse crimper that forms crimps transversely across the stock material. A supply unit of stock material can be stored in a roll (whether pulled from the inside or outside of the roll), a wrap, a fan-folded source, or other suitable form. The stock material can be continuous or perforated. The conversion apparatus feeds the stock material from the supply unit in a first direction, which can be an anti-runout direction.

[0064] The stock material may be any suitable type of protective packaging material, including, for example, flat or rolled paper stock, other padding and void filling materials, inflatable packaging pillows, and the like. Some embodiments may use a supply of other paper or fiber-based materials in sheet form. Other embodiments may use a supply of wound fiber materials such as rope or wire. Other embodiments may use thermoplastic materials, such as a web of plastic material that can be used to form a pillow-shaped packaging material. Examples of paper used include a fan-folded supply unit of stock material having a 30-inch lateral width (e.g., FIG. 24A to FIG. 25D ) and / or 15 inch lateral width of raw material (such as FIG. 22A to FIG. 23D ). Preferably, the sheets are fan-folded into a single layer. In other embodiments, multiple layers of sheets can be fan-folded together so that the padding is made of superimposed sheets that are crumpled together during the conversion process.

[0065] Any suitable stock material can be used. For example, the stock material can have a basis weight of about 20 pounds to about 100 pounds. The stock material can include a paper stock that is stored in a high-density configuration with a first longitudinal end and a second longitudinal end, which is subsequently converted to a low-density configuration by a conversion system. The stock material can be a sheet material strip stored in a fan-shaped folded structure or stored in a coreless roll. The stock material can be formed or stored as a single-layer sheet or a multi-layer sheet material. In the case of using a multi-layer sheet material, the layer can include a plurality of plies. Other types of materials can be used, such as virgin paper and recycled paper based on pulp, newsprint, cellulose and starch compositions, and polymeric or synthetic materials with suitable thickness, weight, and size.

[0066] In some embodiments, the supply unit of the raw material may have a FIG. 22A to FIG. 25D . For example, a foldable material such as paper can be repeatedly folded to form a stack or three-dimensional body. In contrast to a "two-dimensional" material, the term "three-dimensional" body has three dimensions that are not negligible. A continuous sheet (e.g., a sheet of paper, plastic, or foil) can be folded at a plurality of fold lines extending transversely to the longitudinal direction of the continuous sheet or transversely to the feed direction of the sheet. For example, folding a continuous sheet having a substantially uniform width along a transverse fold line can form or define sheet sections having approximately the same width. A continuous sheet can be sequentially folded in opposite or alternating directions to produce an accordion-shaped continuous sheet. For example, folding can form or define sections along the continuous sheet, and these sections can be substantially rectangular.

[0067] For example, sequentially folding a continuous sheet can produce an accordion-shaped continuous sheet having sheet segments of approximately the same size and / or shape as each other. A plurality of adjacent segments defined by fold lines can be generally rectangular and can have the same first dimension, e.g., a dimension corresponding to the width of the continuous sheet, and the same second dimension generally along the longitudinal direction of the continuous sheet. For example, when adjacent segments are in contact with each other, the continuous sheet can be configured as a three-dimensional body or stack in an accordion shape that is formed by the folding and compressed so that the continuous sheet forms a three-dimensional body or stack.

[0068] The fold lines of the stock material can have any suitable orientation relative to each other and to the longitudinal and transverse directions of the continuous sheet. In addition, the stock material units can have transverse folds that are parallel to each other. For example, the segments formed by the fold lines can be compressed to form a three-dimensional body as a rectangular prism. In addition, the stock material can have one or more folds that are not parallel to the transverse folds. In some applications, such as FIG. 24A to FIG. 25D For applications such as those depicted in FIG, the top sheet may be folded in a pattern that more easily facilitates feeding the top sheet into a dunnage converting machine.

[0069] The feedstock material may be provided as any suitable number of discrete feedstock material units. FIG. 23A to FIG. 23D and FIG. 25A to FIG. 25D As shown in , two or more raw material units can be connected together to provide a continuous feed of material into a padding conversion machine. The material can be fed from the connected raw material units sequentially or simultaneously, i.e., in series or in parallel. The raw material units can have various suitable sizes and configurations, and can include stacks or rolls of one or more suitable sheet materials. The term "sheet material" refers to a material that is generally sheet-like and two-dimensional, i.e., two dimensions of the material are substantially greater than a third dimension, so that the third dimension is negligible or minimal compared to the other two dimensions. In addition, the sheet material can be generally flexible and foldable, such as the illustrative material described herein.

[0070] The stock material unit may include an attachment mechanism that connects multiple stock material units, for example, to create a continuous feed of material from multiple discrete stock material units. The respective ends and beginnings of successive rolls may be joined by an adhesive or other suitable means to facilitate daisy-chaining the rolls together to form a continuous stream of sheet material that can be fed into a dunnage conversion machine.

[0071] Folding the continuous sheet along the transverse fold line can form or define a generally rectangular sheet section. The rectangular sheet section can be stacked together by, for example, folding the continuous sheet in alternating directions to form a three-dimensional body with longitudinal, transverse and vertical dimensions. The raw material from the raw material unit can be fed through a feed port (such as the feed port 100 shown in the figure). In some applications, the transverse direction of the continuous sheet of raw material material can be greater than one or more dimensions of the feed port. For example, the transverse dimension of the continuous sheet can be greater than the diameter of the generally circular feed port. Reducing the width of the continuous sheet in this way at the beginning of the conversion process can facilitate its entry into the feed port. The reduced width of the front portion of the continuous sheet can facilitate smoother entry and / or transition of the continuous sheet connected in a daisy-chain manner and / or can reduce or eliminate the capture or tearing of the continuous sheet. In addition, reducing the width of the continuous sheet at the beginning of the continuous sheet can facilitate connecting two or more raw material units together or daisy-chaining. For example, connecting or daisy-chaining materials with tapered sections can be accomplished using smaller connectors or splicing elements than would otherwise be necessary. Also, tapered sections can be more easily manually aligned and / or connected together than full-width sheet sections.

[0072] The figures depict an embodiment of a system 10 for producing dunnage. The system 10 is configured to process a raw material 19 into dunnage 15. The system 10 includes a supply unit 18 of the raw material 19 and a dunnage apparatus 50.

[0073] The dunnage apparatus 50 includes a dunnage conversion machine 60 , a support 12 configured to support the dunnage conversion machine 60 , and a supply station 13 configured to hold a supply unit 18 of a raw material 19 .

[0074] The specific configuration of the support 12 depicted in the figures is disclosed for illustrative purposes only. The support 12 may have other configurations suitable for supporting the dunnage conversion machine 60.

[0075] Likewise, FIG. 22A to FIG. 22D The shelf or basket configuration of the supply station 13 depicted in the drawings is disclosed for illustrative purposes only, and contains supply units 18 in the form of stacks of folded feedstock materials 19. The supply station 13 may have other configurations suitable for supporting (multiple) supply units 18 in a single bundle, in multiple daisy-chained bundles, in a flat configuration, in a coiled configuration, and / or in a curved configuration.

[0076] In other embodiments, the supply station 13 may be FIG. 22A to FIG. 22D 1, 2, or 3. In some embodiments, the dunnage conversion machine 60 and the supply station 13 may be mounted to a basket, shelf, or other type of support structure mounted on the bracket 12. In such an embodiment, the dunnage conversion machine 60 and the supply station 13 do not move relative to each other. In other embodiments, the supply station 13 and the dunnage conversion machine 60 may be fixed relative to each other but not mounted to each other. In other alternative embodiments, the supply station 13 and the dunnage conversion machine 60 may be configured to move relative to each other when mounted together or not mounted together.

[0077] The supply station 13 may support one or more of the supply units 18 of the raw material 19. In some embodiments, the supply station 13 may support multiple supply units 18. In applications where the supply station 13 accommodates multiple supply units 18, the end sheets and starting sheets of adjacent supply units 18 may be connected together before or after being placed on the supply station 13. Connecting or daisy-chaining multiple supply units together may produce a continuous supply of the raw material 19.

[0078] The raw material 19 is converted into the dunnage 15 by following the material path A through the system 10. The material path A is Figures 19 to 21 The material path A has an inlet end that feeds the raw material 19 into the system 10 and an outlet end that allows the padding 15 to exit the system 10 .

[0079] The dunnage conversion machine 60 includes: a housing 61 ; a feed port 100 ; an outlet chute 62 ; a cutting motor assembly 201 ; and a feed motor 301 extending from the housing 61 .

[0080] The feed port 100 includes an inlet chute 102. The inlet chute 102 includes two side panels 110, a top panel 112 and a bottom panel 114. Figure 4 and Figure 5 Each side panel 112 abuts a corresponding side of the top panel 112 and a corresponding side of the bottom panel 114. The feed port 100 defines an inlet 116 and an outlet 118. The inlet chute 102 is attached to the rearward end of the dunnage conversion machine 60 so that the outlet 118 is aligned with the inlet of the dunnage conversion machine 60, as shown in FIG. Figures 10 to 14 The entry chute 102 may be attached to the dunnage conversion machine 60 by suitable means such as fasteners.

[0081] The entry chute 102 defines a portion of a material path A for the stock material 19. In particular, the side panels 110, the top panel 112, and the bottom panel 114 define a channel 120 extending between an inlet 116 and an outlet 118 of the entry chute 102. The stock material 19 enters the channel 120 through the inlet 116. The stock material 19 is pulled through the channel 120 until it reaches the outlet 118, where the stock material 19 exits the entry chute 102 and enters the dunnage conversion machine 60.

[0082] The side panels 110 of the inlet chute 102 are angled inwardly along the length of the feed opening so that the width of the channel 120 decreases between the inlet 116 and the outlet 118. For example, the width of the channel 120 can be approximately equal to the initial width of the feedstock material 19. As the feedstock material 19 is pulled through the channel 120, Figures 10 to 14 The angled orientation of the side panels 110 visible in FIG. 1 causes the side panels 110 to push opposing sides of the feedstock material 19 toward each other, which in turn causes the feedstock material to wrinkle and experience a reduction in its overall width before exiting the feed opening via outlet 118 .

[0083] refer to Fig.11 , the feed port 100 also includes a protrusion or projection 122. The projection 122 is attached to the bottom panel 114 of the entry chute 102 by suitable means such as fasteners. In an alternative embodiment, the projection 122 and the bottom panel 114 can be integrally formed. The projection 122 is attached to the rearward end of the bottom panel 114, that is, to the end of the bottom panel 114 near the inlet 116. The projection 122 extends downwardly from the bottom panel 114.

[0084] The protrusions 122 are symmetrically disposed about the longitudinal centerline of the feed port 100 with respect to the lateral or left-right direction of the feed port 100. The protrusions 122 have a width or left-right dimension that is significantly smaller than the width of the passage 120.

[0085] The protrusion 122 includes a faceted surface 124. The faceted surface 124 faces generally outward, away from the entry chute 102, and is configured to contact and slightly bend the feedstock material 19 before the feedstock material 19 enters the entry chute 102.

[0086] The faceted surface 124 includes two substantially planar upper surface portions 126a, 126b. The upper surface portions 126a, 126b are adjacent to each other and are symmetrically disposed about a lateral or left-right centerline of the protrusion 122. The upper surface portions 126a, 126b are angled toward the direction of travel of the paper stock 19 through the inlet chute 102. In addition, the upper surface portions 126a, 126b are angled relative to each other such that the upper surface portions 126a, 126b are inclined away from each other.

[0087] The facet surface 124 also includes two upper end portions 128a, 128b. The upper end portions 128a, 128b each have a curved profile. The upper end portion 128a abuts the upper surface portion 126a. The upper end portion 128a also abuts the first side 129a of the protrusion 122. The upper end portion 128b abuts the upper surface portion 126b. The upper end portion 128b also abuts the second side 129b of the protrusion 122.

[0088] The facet surface 124 also includes two intermediate surface portions 130a, 130b. The intermediate surface portions 130a, 130b are adjacent to each other and are symmetrically arranged about the transverse centerline of the protrusion 122. In addition, the intermediate surface portions 130a, 130b each abut the lower edge of the corresponding upper surface portion 126a, 126b. The intermediate surface portions 130a, 130b each have a rounded, outwardly curved profile.

[0089] The facet surface 124 also includes two intermediate end portions 132a, 132b. The intermediate end portions 132a, 132b each have a curved profile. The intermediate end portion 132a abuts the intermediate surface portion 130a. The intermediate end portion 132a also abuts the first side 129a of the protrusion 122. The intermediate end portion 132b abuts the intermediate surface portion 130b. The intermediate end portion 132b also abuts the second side 129b of the protrusion 122.

[0090] The faceted surface 124 also includes two substantially planar lower surface portions 134a, 134b. The lower surface portions 134a, 134b abut one another and are disposed symmetrically about a transverse centerline of the protrusion 122. Furthermore, the lower surface portions 134a, 134b each abut a lower edge of a respective intermediate surface portion 130a, 130b. The lower surface portions 134a, 134b are angled toward a direction of travel of the paper stock 19 through the inlet chute 102. Furthermore, the lower surface portions 134a, 134b are angled relative to one another such that the lower surface portions 134a, 134b are inclined away from one another.

[0091] The facet surface 124 also includes two lower end portions 136a, 136b. The lower end portions 136a, 136b each have a curved profile. The lower end portion 136a abuts the lower surface portion 134a. The lower end portion 136a also abuts the first side 129a of the protrusion 122. The lower end portion 136b abuts the lower surface portion 134b. The lower end portion 136b also abuts the second side 129b of the protrusion 122.

[0092] As the stock material 19 is pulled from the supply station 13 and enters the input chute 102, the central portion of the stock material 19 aligned with the protrusion 122 passes through the small face surface 124 and is bent by the small face surface. In particular, the central portion of the stock material 19 passes through the lower surface portions 134a, 134b and the lower end portions 136a, 136b in a substantially flat state. This portion of the stock material 19 then passes through the intermediate surface portions 130a, 130b and the intermediate end portions 132a, 132b and undergoes a change in direction due to the curved profiles of the intermediate surface portions 130a, 130b and the intermediate end portions 132a, 132b. This change in direction causes the stock material 19 to bend. When the central portion of the stock material 19 is pulled through the upper surface portions 126a, 126b and the upper end portions 128a, 128b, the central portion of the stock material then returns to a substantially flat state. Bending the stock material 19 in this manner may make the stock material 19 more pliable for conversion into dunnage in the dunnage conversion machine 60 .

[0093] like Fig.19 , the stock material 19 is then pulled through the curved lip 140 defining the leading edge of the bottom panel 114, and then into the channel 120 within the entry chute 102. The stock material 19 is then pulled through the substantially planar surface 142 of the bottom panel 114. As noted above, the side panels 110 are angled inwardly such that the width of the channel 120 decreases between the entrance 116 and the exit 118 of the entry chute 102. This decrease in width, combined with the increase in flexibility of the stock material 19 due to the bending of the stock material 19 over the tabs 122, causes the stock material 19 to experience a decrease in width, which in turn causes the stock material 19 to crumple and form folds along its lengthwise direction, thereby producing a continuous length of the pad 15.

[0094] In alternative embodiments, facet surface 124 may have shapes other than the specific shapes described herein. In other alternative embodiments, a non-facet surface may be used in place of facet surface 124.

[0095] As used herein, the term "substantially planar surface" may refer to a surface that is smooth to the point of appearing completely flat. For example, a "substantially planar surface" may be a completely flat surface. Also, a "substantially planar surface" may be a surface having a large radius of curvature, for example, 10 feet or more.

[0096] The dunnage conversion machine 60 includes a frame 178, a first roller 180, and a second roller 182. The dunnage conversion machine 60 also includes a drive motor (not shown) housed within a motor housing 186 and supported by the frame 178.

[0097] The stock material 19 passes between the first roller 180 and the second roller 182, and the first roller and the second roller move along the material path A. The second roller 182 is idle, that is, not directly driven by the motor. The second roller 182 is spring biased toward the first roller 180 so that the stock material 19 is clamped between the first roller 180 and the second roller 182, and the friction generated between the rotating first roller 180 and the stock material 19 causes the stock material 19 to move along the material path. In addition, the pressure applied by the first roller 180 and the second roller 182 on the stock material 19 forms wrinkles in the stock material along the folds formed in the feed port 100. The drive motor is reversible so that the direction of travel of the stock material 19 through the dunnage conversion machine 60 can be reversed.

[0098] Alternative embodiments of the system 10 may be equipped with means for converting the stock material 19 into the dunnage 15 using hardware other than rollers, such as a paper crumpler.

[0099] refer to Figures 3 to 6 and Figures 14 to 17 The dunnage conversion machine 60 also includes a cutting mechanism 200 and a housing 204, the cutting mechanism including a cutting device in the form of a blade 202. The housing 204 is coupled to the frame 178 and supports the blade 202. Figure 6 As shown in FIG. 2 , the blade 202 has a serrated cutting edge 206. In alternative embodiments, the cutting edge 206 may have other shapes. The blade 202 is angled in the direction of the material path A.

[0100] In alternative embodiments, the cutting device may have a configuration other than the blade 202. For example, in alternative embodiments, the cutting device may be configured as a wire, a knife, or another type of cutting member.

[0101] The cutting mechanism 200 also includes a duckbill or cover 208. The first end of the cover 208 is connected to the frame 178 by a pin or other suitable means so that the cover 208 can be moved relative to the frame 178 and the blade 202. Figure 4 , Fig.14 and Fig.16 The lowered or closed position depicted in Figure 3 , Figure 5 , Figure 6 , Fig.15 and Fig.17 Pivots between the raised or open positions depicted.

[0102] The second roller 182 is mounted for rotation on the cover 208. The second roller 182 is positioned on the cover 208 so that when the cover is in the closed position, the second roller 182 contacts the first roller 180. A user can load the stock material 19 into the dunnage conversion machine 60 by raising the cover 208 to its open position, placing the leading end of the stock material 19 on the first roller 180, and then lowering the cover 208 to its closed position so that the stock material 19 is clamped between the first roller 180 and the second roller 182.

[0103] The cutting mechanism 200 also includes a clamp 222. The ends of the clamp 222 are coupled to freestanding ends of the cover 208 by pins or other suitable means that allow the clamp 222 to rotate between a raised or open position and a lowered or closed position.

[0104] The cutting mechanism 200 further includes a drive mechanism 224 mounted on the cover 208. The drive mechanism 224 is Fig.16 and Fig.17 . The drive mechanism 224 is configured to move the clamp 222 between the open position and the closed position. The drive mechanism 224 includes: a drive motor (not shown); a first sprocket 226, which is directly driven by the drive motor; a second sprocket 228, which is connected to a pin that couples the clamp 222 to the cover 208; and a linkage 229, which transfers the torque applied by the drive motor to the first sprocket 226 to the second sprocket 228, so that the second sprocket 228 rotates the cover 208 between the closed position and the open position. This particular configuration for the drive mechanism 224 is described for illustrative purposes only. Alternative embodiments may include drive mechanisms having other configurations.

[0105] The cutting mechanism 200 also includes one or more sensors 220 mounted on the housing 204 and communicatively coupled to a controller (not shown) of the dunnage conversion machine 60. The sensor 220 may be, for example, an optical sensor. Other types of sensors may be used in alternative embodiments. When the clamp 222 is in its closed position, the sensor 220 is located near the freestanding end of the clamp 222. The sensor 220 is configured to detect the presence of dunnage 15 proximate the sensor 220.

[0106] The cutting mechanism 200 also includes one or more buffers 230. The buffers 230 are arranged Figure 4 , Figure 5 and Fig.12. The buffer 230 is mounted on the inwardly facing surface of the clamp 222, at or near the freestanding end of the clamp 222. The buffer 230 can be configured as a plurality of small knobs or buttons protruding from the clamp 222. In particular, the buffer 230 can be configured as one or more elongated members oriented transversely to the material path A. The clamp 222, the buffer 230 and the housing 204 of the cutting mechanism 200 are configured so that when the clamp 222 is in the closed position, the padding 15 that has passed through the first roller 180 and the second roller 182 is captured between the buffer 230 and the adjacent surfaces of the housing 204. The buffer 230 can be formed of a material, such as an elastomeric material, that generates sufficient friction to help retain the cut liner piece 15 between the buffer 230 and the housing 204.

[0107] The padding converter 60 can be configured to operate in a mode in which the padding converter 60 produces a predetermined length of padding 15, wherein the predetermined length is selected by the user. The padding converter 60 can also operate in a mode in which the user can dispense a desired, non-predetermined length of padding by pressing a button or a foot pedal until the desired length has been dispensed. In either operating mode, the cutting mechanism is configured to cut or cut out a portion of the padding that has passed through the blade 202. In particular, when the first roller 180 is rotated by its associated drive motor, the clamp 222 is in its raised position. As discussed above, the raw material 19 is pulled between the first roller 180 and the second roller 182 from the supply station 13. The folds formed in the raw material 19 in the feed port 100 are wrinkled as the raw material 19 passes between the first roller 180 and the second roller 182, and are compressed by the first roller and the second roller.

[0108] In response to input from the controller of the dunnage conversion machine 60, once the predetermined length or other desired length of dunnage 15 has been dispensed, the drive motor is deactivated, which in turn causes the first roller 180 and the second roller 182 to stop pulling the stock material 19 through the dunnage conversion device 60. At this time, the controller also sends input to the drive motor of the drive mechanism 224, causing the drive motor to be enabled. When enabled, the drive motor rotates the clamp 222 to its lowered position. When the clamp 222 is in its lowered position, the buffer 224 contacts the dunnage and pushes the dunnage toward the adjacent surface of the housing 204.

[0109] Next, the controller issues a command to the drive motor that causes the drive motor to operate in a reverse direction, i.e., in a direction opposite to the direction in which the drive motor causes the first roller 108 to pull the stock material 19 and the pad material 15 in the direction of the material path A. When the clamp 222 is in its closed position, the pad material 15 is caused to wrap around the outwardly angled blade 202. Thus, the reverse direction of the drive motor will pull the pad material 15 past the cutting edge of the blade 202, cutting out a portion of the pad material 15 downstream of the blade 202.

[0110] The bumper 230 is biased toward the housing 204 by the drive mechanism 224. Thus, the cut-out portion of the padding material is held in place by the bumper 230 and the adjacent surface of the housing 204. Furthermore, the sensor 220 located near the location where the padding piece 15 is held registers the presence of the padding material 15 and generates an output that is interpreted by the controller as an indication that the padding piece 15 is held by the clamp 222. The controller will not initiate or allow another cycle to be initiated, i.e., the production of another padding piece 15, until the sensor 220 indicates that the cut-out padding piece 15 is no longer held by the clamp 222.

[0111] The user can retrieve the padding sheet 15 by grabbing the padding sheet and applying a force sufficient to pull the padding sheet from between the buffer 230 and the housing 204. Once the padding sheet 15 has been removed from the field of view of the sensor 220, the sensor 220 records the absence of the padding sheet 15 and generates an output, which is interpreted by the controller as an indication that the clamp 222 no longer holds the padding sheet 15. In response, the controller sends an input to the motor of the drive mechanism 224, which causes the motor to rotate the clamp 222 to its raised position. If the padding conversion machine 60 is operated in a mode that automatically produces the next padding sheet 15 when the previous padding sheet is removed, the controller will enable the drive motor to start a cycle of producing another padding sheet 15. If the padding conversion machine is operated in a mode that produces the next padding sheet 15 when receiving a user input, the controller will start the next production cycle when receiving the user input.

[0112] Unless specifically stated otherwise or otherwise understood in the context of use, conditional language such as (among other things) "may," "could," or "might" is generally intended to convey that certain embodiments may include, while other embodiments do not include, certain features, elements, and / or operations. Thus, such conditional language is generally not intended to imply that features, elements, and / or methods are in any way required for one or more embodiments, or that such features, elements, and / or methods are included in any particular embodiment or will be performed in any particular embodiment.

[0113] Many modifications and other embodiments of the disclosure set forth herein will be apparent with the benefit of the foregoing description and the teachings presented in the associated drawings. Therefore, it should be understood that the disclosure is not limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used only in a general and descriptive sense and not for the purpose of limitation.

Claims

1. A dunnage conversion machine comprising: a drive member configured to deform the stock material into a continuous length of mat material; as well as Cutting mechanism, including: a cutting device configured to cut pieces of dunnage from the continuous length of dunnage; as well as A clamp is configured to exert a force on the dunnage sheet to hold the dunnage sheet on the dunnage conversion machine.

2. The dunnage conversion machine of claim 1, wherein: The drive member comprises one or more rollers.

3. The dunnage conversion machine of claim 1, wherein: The cutting device comprises a blade.

4. The dunnage conversion machine of claim 1, wherein: The clamp is also configured to move between a first position and a second position, wherein the clamp exerts a force on the spacer sheet in the first position.

5. The dunnage conversion machine of claim 4, wherein: The clamp is further configured such that when the clamp is in the second position, the clamp does not hold the gasket sheet.

6. The dunnage conversion machine of claim 5, further comprising a controller, wherein: The cutting mechanism further includes: a sensor communicatively coupled to the controller and configured to detect the presence of the pad sheet using a sensing field of the sensor; and a drive mechanism communicatively coupled to the controller and configured to move the clamp between the first position and the second position of the clamp; and the controller being configured to generate an output when the spacer piece is removed from a sensing field of the sensor; The output, when received by a drive mechanism, causes the drive mechanism to move the clamp from the first position to the second position.

7. The dunnage conversion machine of claim 1, wherein: The clamp is also configured to hold the dunnage sheet against an adjacent surface of the dunnage conversion machine with sufficient compression to prevent the dunnage sheet from falling from the dunnage conversion machine.

8. The dunnage conversion machine of claim 7, further comprising a housing configured to support the cutting device, wherein the clamp is further configured to hold the cut dunnage piece against the housing.

9. The dunnage conversion machine of claim 7, wherein: The clamp is also configured to hold the dunnage sheet against the adjacent surface of the dunnage conversion machine with sufficient compression to retain the dunnage sheet on the dunnage conversion machine until the dunnage sheet is pulled from the dunnage conversion machine.

10. The dunnage conversion machine of claim 4, wherein: The cutting mechanism also includes a bumper mounted on the clamp and configured to contact and hold the gasket sheet when the clamp is in the first position.

11. The dunnage conversion machine of claim 6, wherein: The drive mechanism further includes at least one roller configured to feed the continuous length of dunnage to the cutting mechanism in a first direction; and The drive mechanism is also configured to reverse the rotation direction of the at least one roller when the clamp is in the first position in response to input from the controller, so that the drive mechanism pulls the continuous length of pad material in a second direction opposite to the first direction, so that the cutting device cuts the pad sheet from the continuous length of pad material.

12. The dunnage conversion machine of claim 11, wherein: The clamp is also configured such that when the drive mechanism pulls the continuous length of dunnage in the second direction, a force applied by the clamp prevents the continuous length of dunnage from moving in the second direction.

13. The dunnage conversion machine of claim 11, wherein: The cutting device is a blade; and The clamp is also configured to wrap the continuous length of pad material around the blade when the clamp is in the first position.

14. The dunnage conversion machine of claim 10, wherein: An outer surface of the bumper includes a bonding material.

15. The dunnage conversion machine of claim 10, wherein: The bumper comprises an elastomeric material.

16. The dunnage conversion machine of claim 6, wherein: the output generated by the controller is a first output when the spacer piece is removed from the sensing field of the sensor; The controller is further configured to generate a second output when the sensor detects that the spacer piece is within the sensing field of the sensor; and The second output, when received by the drive mechanism, causes the drive mechanism to maintain the clamp in the first position.

17. The dunnage conversion machine of claim 1, wherein: The clamp is configured to retain the cut gasket piece at a location in the cutting assembly downstream of the blade.

18. A system for producing litter, the system comprising: a dunnage conversion machine including a drive member configured to deform stock material into dunnage; as well as A feed port configured to feed the stock material into the dunnage conversion machine, wherein the feed port includes an entry chute connected to the dunnage conversion machine, and a protrusion connected to the entry chute, wherein the protrusion includes a plurality of surface portions configured to cause the stock material to bend as the stock material passes through the plurality of surface portions.

19. The system of claim 18, wherein: The protrusion extends downwardly from an inlet end of the inlet chute.

20. The system of claim 18, wherein: The protrusion includes a faceted surface including the plurality of surface portions.

21. The system of claim 18, wherein: The plurality of surface portions include a substantially planar upper surface portion and an outwardly curved intermediate surface portion adjacent the upper surface portion; and a substantially planar lower surface portion adjacent the intermediate surface portion.

22. The system of claim 21, wherein: The upper surface portion is angled upward in a direction of travel of the feedstock material into the feed opening; and the lower surface portion is angled downward in a direction of travel of the feedstock material into the feed opening.

23. The system of claim 21, wherein: The upper surface portion is a first upper surface portion; The intermediate surface portion is a first intermediate surface portion; The intermediate surface portion is a first lower surface portion; as well as The plurality of surface portions further comprises: a second upper surface portion, the second upper surface portion being adjacent to the first upper surface portion, the first upper surface portion and the second upper surface portion being symmetrically disposed about a transverse centerline of the protrusion; a second intermediate surface portion, the second intermediate surface portion adjoining the first intermediate surface portion, the first intermediate surface portion and the second intermediate surface portion being symmetrically disposed about a transverse centerline of the protrusion; and A second lower surface portion is disposed adjacent to the first lower surface portion, the first lower surface portion and the second lower surface portion being symmetrically disposed about a transverse center line of the protruding portion.

24. The system of claim 23, wherein the plurality of surface portions further comprises: a first upper end portion and a second upper end portion, each having a curved profile, the first upper end portion abutting a first side of the protrusion and the first upper surface portion, the second upper end portion abutting a second side of the protrusion and the second upper surface portion; a first intermediate end portion and a second intermediate end portion, each having a curved profile, the first intermediate end portion adjoining the first side and the first intermediate surface portion, the second intermediate end portion adjoining the second side and the second intermediate surface portion; A first lower end portion and a second lower end portion, each having a curved profile, the first lower end portion adjoining the first side and the first lower surface portion, the second lower end portion adjoining the second side and the second lower surface portion.

25. The system of claim 18, wherein: The dunnage conversion machine includes one or more rollers.

Images