Dunnage converter, apparatus and system for manufacturing dunnage

Abstract

The dunnage converting machine includes a drive mechanism configured to deform a stock material into continuous lengths of dunnage. The machine also includes a cutting device configured to cut dunnage pieces from the continuous lengths of dunnage. The cutting device includes a grip configured to move to a closed position, the grip exerting a force on the dunnage piece and holding the dunnage piece on the machine until the dunnage piece is pulled away from the machine, at which point the grip moves to an open position and the machine advances the continuous length of dunnage to initiate the next cutting cycle.

Description

Technical Field

[0001] The present disclosure relates to a system for converting paper and other materials into dunnage for use as packaging materials.

Background Art

[0002] Paper-based protective packaging, i.e., dunnage, is manufactured by crushing or otherwise deforming paper materials. More specifically, paper dunnage is manufactured by running a generally continuous strip of paper through a dunnage converter. The continuous strip of paper can be provided, for example, from a roll of paper or a bundle of paper folded in a fan shape. The dunnage converter uses, for example, opposing rollers through which the stock material passes to convert the stock material into a lower density dunnage material. The rollers grasp and pull the stock material from the roll or stack and deform the stock material as it passes between the rollers. The resulting dunnage can be cut to a desired length to effectively fill the void space within a container holding a product. Individual pieces of dunnage material can be manufactured as needed for a human operator or automated device performing a packaging operation, and the individual pieces are typically grasped or manipulated by the operator or equipment immediately after being cut. The operator or automated device typically instructs the production of each piece of dunnage when needed during the packaging operation.

Summary of the Invention

Means for Solving the Problems

[0003] In one aspect of the disclosed technology, a dunnage conversion machine includes a drive mechanism configured to deform a stock material into a continuous length of dunnage, and a cutting mechanism. The cutting mechanism includes a cutting device configured to cut a piece of dunnage from the continuous length of dunnage, and a grip configured to apply a force to the piece of dunnage to hold the piece of dunnage in the dunnage conversion machine.

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

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

[0006] In another aspect of the disclosed technology, the grip is further configured to move between a first position where the grip applies a force to the piece of dunnage and a second position.

[0007] In another aspect of the disclosed technology, the grip is further configured such that the grip does not hold the piece of dunnage when the grip 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 communicatively coupled to the controller and configured to detect the presence of a piece of dunnage using a sensing field of the sensor, and a drive mechanism communicatively coupled to the controller and configured to move the grip between the first position and the second position of the grip.

[0009] The controller is configured to generate an output when the debris piece is removed from the sensing area of the sensor. When the output is received by the drive mechanism, the drive mechanism moves the gripper from a first position to a second position.

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

[0011] In another aspect of the disclosed technology, it further includes a housing configured to support a cutting device by the debris converter. The gripper is further configured to hold the cut debris piece against the housing.

[0012] In another aspect of the disclosed technology, the gripper is further configured to hold the debris piece against an adjacent surface of the debris converter with sufficient compression to hold the debris piece on the debris converter until the debris piece is pulled from the debris converter.

[0013] In another aspect of the disclosed technology, a cutting mechanism is attached to the gripper, and it further includes a bumper configured to contact and hold the debris piece when the gripper is in the first position.

[0014] In another aspect of the disclosed technology, the drive mechanism further includes at least one roller configured to supply a continuous length of debris in a first direction to the cutting mechanism. The drive mechanism is further configured to reverse the rotational direction of the at least one roller while the gripper is in the first position in response to an input from the controller, so that the drive mechanism pulls the continuous length of debris in a second direction opposite to the first direction and causes the cutting device to cut a debris piece from the continuous length of debris.

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

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

[0017] In another aspect of the disclosed technology, the outer surface of the bumper includes a tacky 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 a piece of webbing is removed from the sensing area of the sensor is a first output, and the controller is further configured to generate a second output when the sensor detects that the piece of webbing is within the sensing area of the sensor. The second output, when received by the drive mechanism, causes the drive mechanism to maintain the gripper in the first position.

[0020] In another aspect of the disclosed technology, the gripper is configured to hold a piece of webbing cut at a downstream position of the blade within the cutting assembly.

[0021] In another aspect of the disclosed technology, a system for generating webbing includes a webbing converter having a drive mechanism configured to deform stock material into webbing and an inlet configured to supply the stock material to the webbing converter. The inlet includes an inlet chute connected to the webbing converter and a protrusion connected to the inlet chute. The protrusion includes a plurality of surface portions configured to bend the stock material as the stock material passes over the surface portions.

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

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

[0024] In another aspect of the disclosed technology, the plurality of surface portions also include a substantially flat upper surface portion, an outwardly curved intermediate surface portion adjacent to the upper surface portion, and a substantially flat lower surface portion adjacent to the intermediate surface portion.

[0025] In another aspect of the disclosed technology, the upper surface portion forms an upward angle with respect to the direction of movement of the stock material towards the inlet, and the lower surface portion forms a downward angle with respect to the direction of movement of the stock material towards the inlet.

[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 includes a second upper surface portion adjacent to the first upper surface portion. The first and second upper surface portions are symmetrically arranged about the lateral centerline of the protrusion. The plurality of surface portions also includes a second intermediate surface portion adjacent to the first intermediate surface portion. The first and second intermediate surface portions are symmetrically arranged about the lateral 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 and second lower surface portions are symmetrically arranged about the lateral centerline of the protrusion.

[0029] In another aspect of the disclosed technology, the plurality of surface portions further includes a first upper end portion and a second upper end portion each having a curved outer shape. The first upper end portion is adjacent to the first side portion and the first upper surface portion of the protrusion, and the second upper end portion is adjacent to the second side portion and the second upper surface portion of the protrusion.

[0030] The plurality of surface portions further include first and second intermediate ends each having a curved outer shape. The first intermediate end is adjacent to the first side portion and the first intermediate surface portion. The second intermediate end is adjacent to the second side portion and the second intermediate surface portion.

[0031] The plurality of surface portions further include first and second lower ends each having a curved outer shape. The first lower end is adjacent to the first side portion and the first lower surface portion. The second lower end is adjacent to the second side portion and the second lower surface portion.

[0032] In another aspect of the disclosed technology, the dunnage converter includes one or more rollers.

Brief Description of the Drawings

[0033] The following drawings are examples of specific embodiments of the present disclosure and, therefore, do not limit the scope of the present disclosure. The drawings are not to scale and are intended to be used in conjunction with the description in the following detailed description. Embodiments of the present disclosure are described below in conjunction with the accompanying drawings, and like numbers indicate like elements.

[0034]

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DETAILED DESCRIPTION OF THE INVENTION

[0035] The following description omits or briefly describes conventional features of the disclosed technology that will be apparent to those of ordinary skill in the art. References to various embodiments do not limit the scope of the claims appended hereto. Further, any example described herein is intended to be non-limiting and is intended merely to describe some of the many possible embodiments for the appended claims. Additionally, the specific features described herein may be used in combination with each of the other features described, in various possible combinations and permutations. Those of ordinary skill in the art will know how to use the present invention in combination with ordinary experimentation to achieve other results not specifically disclosed in the examples or embodiments.

[0036] Unless otherwise specifically defined herein, all terms should be given their broadest possible interpretation, including the meanings implied by the specification, as understood by those skilled in the art, and / or as defined in dictionaries, treatises, etc. Unless otherwise defined, all technical and scientific terms used herein shall have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed technology pertains. Also, as used in this specification and the appended claims, the singular form shall include the plural unless otherwise specified, and when the terms "comprising" and / or "including" are used herein, they specify the presence of the stated features, elements, and / or components, but it should be noted that they do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Furthermore, methods, apparatuses, and materials similar or equivalent to those described herein may also be used in the practice or testing of the disclosed technology.

[0037] Various embodiments of the disclosed technology are provided throughout this disclosure. The use of these embodiments is merely illustrative and in no way limits the scope and meaning of the invention or any of the illustrated forms. Similarly, the invention is not limited to any particular preferred embodiment described herein. Indeed, modifications and variations of the invention may be apparent to those skilled in the art upon reading this specification and can be made without departing from the spirit and scope thereof. Accordingly, the invention should be limited only by the terms of the claims and the full scope of equivalents to which the claims are entitled.

[0038] Certain relationships between the characteristics of a suppressor are described herein using the terms "substantially" or "substantially equal." As used herein, the terms "substantially" and "substantially equal" indicate that the equal relationship is not an exact relationship and do not exclude functionally similar variations therefrom. Unless otherwise specified in the context or description, the use of the terms "substantially" or "substantially equal" in relation to two or more recited dimensions includes variations that do not change the least significant digit of the dimension using the mathematical and industrial principles recognized in the art for equal relationships (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 an exact relationship and does not exclude functionally similar variations. As used herein, the term "substantially orthogonal" indicates that the orthogonal relationship is not an exact relationship and does not exclude functionally similar variations.

[0039] A system for converting a high-density stock material into low-density dunnage is disclosed. The stock material is processed by longitudinal crumple machines that form creases longitudinally in the stock material to form dunnage, or by cross crimple machines that form creases transversely in the stock material. The stock material supply unit can store the stock material in the form of a roll (drawn from the inside or outside of the roll), wind, a fan-folded supply source, or other suitable form. The stock material can be continuous or perforated. The conversion device feeds the stock material from the supply unit in a first direction, and the first direction can be an anti-run out direction.

[0040] The stock material can be any suitable type of protective packaging material, including, for example, flat or roll paper stock, other dunnage and void fill materials, inflatable packaging pillows, etc. Some embodiments can use a supply of other paper or fiber-based materials in sheet form. Other embodiments can use a supply of wound fiber materials such as ropes or threads. Other embodiments can use thermoplastic materials such as a web of plastic material that can be used to form pillow packaging materials. Examples of the paper used include a fan-folded supply unit having a stock material with a 30-inch lateral width as shown in FIGS. 24A-25D and / or FIGS. 22A-23D and / or as shown in a 15-inch lateral width. Preferably, these sheets are folded as a single layer. In other embodiments, multiple layers of the sheet can be folded together such that the dunnage is made from the stacked sheets that are crumpled together in the conversion process.

[0041] Any suitable stock material can be used. For example, the stock material can have a basis weight of from about 20 pounds to about 100 pounds. The stock material can include paper stock stored in a high-density configuration having a first longitudinal end and a second longitudinal end, which paper stock is later converted to a low-density configuration by a conversion system. The stock material can be a ribbon of sheet material stored in a fan-fold structure or coreless rolls. The stock material can be formed or stored as a single-ply or multiple-ply material. When multiple-ply materials are used, the layers can include multiple plies. Other types of materials can be used, such as pulp-based virgin and recycled paper, newsprint, cellulose and starch compositions, and poly or synthetic materials of suitable thickness, weight, and dimensions.

[0042] In some embodiments, the stock material supply unit may have a configuration that is folded in a fan shape as shown in FIGS. 22A-25D. For example, a foldable material such as paper can be repeatedly folded to form a stack or a three-dimensional body. In contrast to a "two-dimensional" material, the term "three-dimensional body" has three dimensions that cannot all be ignored. A continuous sheet, such as a sheet of paper, plastic, or foil, can be folded along a plurality of fold lines that extend transverse to the longitudinal direction of the continuous sheet or transverse to the supply 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 substantially the same width. The continuous sheet can be continuously folded in opposite or alternating directions to produce an accordion-shaped continuous sheet. For example, the folds can form or define sections along the continuous sheet, and the sections can be substantially rectangular.

[0043] For example, by sequentially folding a continuous sheet, an accordion-shaped continuous sheet having sheet portions that have substantially the same size and / or shape as each other can be generated. The plurality of adjacent portions defined by the fold lines can generally be rectangular and can have the same first dimension, for example, a dimension corresponding to the width of the continuous sheet, and generally the same second dimension along the longitudinal direction of the continuous sheet. For example, when adjacent sections are in contact with each other, the continuous sheet is configured in an accordion shape that is formed and compressed by the folds as a three-dimensional body or laminate, and the continuous sheet forms a three-dimensional body or laminate.

[0044] The fold lines of the stock material can have any suitable orientation relative to the longitudinal and transverse directions of the continuous sheet. Also, the stock material units can have transverse folds that are parallel to each other. For example, the portions formed by the folding lines can be compressed to form a three-dimensional body in the shape of a rectangular prism. Also, the stock material can have one or more folds that are non-parallel to the transverse folds. In some applications, such as those shown in FIGS. 24A - 25D, the top sheet can be folded in a pattern that makes it easier to feed the top sheet into the dunnage converting machine.

[0045] The stock material can be provided as any suitable number of separate stock material units. In some embodiments, as shown in FIGS. 23A - 23D and FIGS. 25A - 25D, two or more stock material units can be connected to each other to provide a continuous supply of material to the dunnage converting machine. The material can be supplied sequentially or simultaneously from the connected stock material units, i.e., in series or in parallel. The stock material units can have various suitable sizes and configurations and can include one or more stacks or rolls of suitable sheet material. The term "sheet material" generally refers to a sheet-like, two-dimensional material, i.e., the two dimensions of the material are sufficiently larger than the third dimension such that the third dimension is negligible or very small compared to the other two dimensions. Also, the sheet material can generally be flexible and foldable, such as the exemplary materials described herein.

[0046] The stock material units can include, for example, an attachment mechanism for connecting a plurality of stock material units to generate a continuous material supply. The respective ends and starting portions of successive rolls can 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 supplied to the dunnage converting machine.

[0047] Folding a continuous sheet along transverse fold lines can generally form or define a generally rectangular sheet portion. The rectangular sheet portions can be stacked together, for example, by folding the continuous sheet in alternating directions to form a three-dimensional body having longitudinal, transverse, and vertical dimensions. Stock material from a stock material unit can be supplied through an inlet such as inlet 100 as shown in the figure. In some applications, the transverse direction of the continuous sheet of stock material can be made larger than one or more dimensions of the inlet. For example, the transverse dimension of the continuous sheet can generally be made larger than the diameter of a generally round inlet. Thus, by reducing the width of the continuous sheet at the start of the conversion process, passage of the continuous sheet into the inlet can be facilitated. Reducing the width of the leading portion of the continuous sheet can facilitate smoother entry and / or transition of the daisy-chain connected continuous sheet and / or can reduce or eliminate snagging or tearing of the continuous sheet. Further, reducing the width of the continuous sheet at the start can facilitate connecting or daisy-chain connecting two or more stock material units to each other. For example, connection or daisy-chain connection of materials having tapered portions can be achieved using smaller connectors or splice elements than normal. Also, the tapered portions can be easier to manually align and / or connect together compared to full-width sheet portions.

[0048] The figure shows an embodiment of a system 10 for manufacturing dunnage. System 10 is configured to process stock material 19 into dunnage 15. System 10 includes a supply unit 18 for the stock material 19 and a dunnage apparatus 50.

[0049] The dunnage device 50 includes a dunnage converter 60, a support 12 configured to support the dunnage converter 60, and a supply station 13 configured to hold a supply unit 18 of the stock material 19.

[0050] The specific configuration of the support 12 shown in the figure is disclosed only for illustrative purposes. The support 12 can have other configurations suitable for supporting the dunnage converter 60.

[0051] Similarly, the shelf or basket-type configuration of the supply station 13 shown in FIGS. 22A-22D that houses the supply unit 18 in the form of a stack of folded stock material 19 is disclosed only for illustrative purposes. The supply station 13 can have other configurations suitable for supporting the supply unit 18 in single bundles, multiple daisy chained bundles, a flat configuration, a rolled configuration, and / or a curved configuration.

[0052] In other embodiments, the supply station 13 may be other types of support structures attached to a basket, shelf, or stand 12 as shown in FIGS. 22A-22D. In such embodiments, the dunnage converter 60 and the supply station 13 do not move relative to each other. In other embodiments, the supply station 13 and the dunnage converter 60 are fixed relative to each other but not attached to each other. In yet other embodiments, the supply station 13 and the dunnage converter 60 may be configured to move relative to each other while attached or not attached together.

[0053] The supply station 13 can support one or more of the supply units 18 of the stock material 19. In some embodiments, the supply station 13 can support a plurality of supply units 18. In applications where a plurality of supply units 18 are accommodated by the supply station 13, the end sheets and start sheets of adjacent supply units 18 may be connected together before or after being disposed on the supply station 13. By connecting or daisy-chaining a plurality of supply units together, a continuous supply of the stock material 19 can be generated.

[0054] The stock material 19 is converted into the dunnage 15 by traveling through the material path A of the system 10. The material path A is shown in FIGS. 19-21. The material path A has an inlet end where the stock material 19 is supplied to the system 10 and an outlet end where the dunnage 15 exits the system 10.

[0055] The dunnage converter 60 includes an enclosure 61, an intake 100, an outlet chute 62, a cutting motor assembly 201, and a supply motor 301 extending from the enclosure 61.

[0056] The intake 100 includes an inlet chute 102. The inlet chute 102 includes two side panels 110, an upper panel 112, and a lower panel 114 as shown in FIGS. 4 and 5. Each side panel 112 is adjacent to respective sides of the upper panel 112 and respective sides of the lower panel 114. The intake 100 defines an inlet 116 and an outlet 118. The inlet chute 102 is attached to the rear end of the dunnage converter 60 such that the outlet 118 is aligned with the inlet of the dunnage converter 60 as shown in FIGS. 10-14. The inlet chute 102 can be attached to the dunnage converter 60 by suitable means such as fasteners.

[0057] The inlet chute 102 defines a portion of the material path A for the stock material 19. In particular, the side panel 110, the top panel 112, and the bottom panel 114 define a passageway 120 that extends between the inlet 116 and the outlet 118 of the inlet chute 102. The stock material 19 enters the passageway 120 via the inlet 116. The stock material 19 is drawn through the passageway 120 until it reaches the outlet 118, at which point the stock material 19 exits the inlet chute 102 and enters the dunnage converter 60.

[0058] The side panel 110 of the inlet chute 102 is inclined inwardly along the length of the intake towards the outlet 118 such that the width of the passageway 120 decreases. For example, the width of the passageway 120 can be approximately equal to the initial width of the stock material 19. As the stock material 19 is drawn through the passageway 120, due to the angled orientation of the side panel 110 as seen in FIGS. 10 - 14, the side panel 110 presses the opposing sides of the stock material 19 towards each other, thereby crumpling the stock material and reducing its overall width before it exits the intake via the outlet 118.

[0059] Referring to FIG. 11, the intake 100 also includes a protrusion 122. The protrusion 122 is attached to the bottom surface 114 of the inlet chute 102 by suitable means such as fasteners. In another embodiment, the protrusion 122 and the bottom panel 114 can be integrally formed. The protrusion 122 is attached to the rear end of the bottom panel 114, i.e., the end of the bottom panel 114 proximate to the inlet 116. The protrusion 122 extends downwardly from the bottom surface panel 114.

[0060] The protrusions 122 are symmetrically disposed laterally across the intake 100 about the longitudinal centerline of the intake 100. The protrusions 122 have a width that is substantially smaller than the width of the passageway 120, i.e., a lateral dimension from side to side.

[0061] The protrusion 122 includes a faceted surface 124. The faceted surface 124 generally faces outward away from the inlet chute 102 and is configured to contact and slightly bend the stock material 19 before the stock material 19 enters the inlet chute 102.

[0062] The faceted surface 124 includes two substantially flat upper surface portions 126a, 126b. The upper surface portions 126a, 126b are adjacent to each other and are symmetrically arranged about the lateral centerline or left - right centerline of the protrusion 122. The upper surface portions 126a, 126b are inclined in the advancing direction of the paper stock 19 passing through the inlet chute 102. Also, the upper surface portions 126a, 126b are angled with respect to each other, and as a result, the upper surface portions 126a, 126b are inclined away from each other.

[0063] The faceted surface 124 also includes two upper end portions 128a, 128b. The upper end portions 128a, 128b each have a curved outer shape. The upper end portion 128a is adjacent to the upper surface portion 126a. The upper end portion 128a is also adjacent to the first side portion 129a of the protrusion 122. The upper end portion 128b is adjacent to the upper surface portion 126b. The upper end portion 128b is also adjacent to the second side portion 129b of the protrusion 122.

[0064] The faceted surface 124 further includes two intermediate surface portions 130a, 130b. The intermediate surface portions 130a, 130b are adjacent to each other and are symmetrically arranged about the lateral centerline of the protrusion 122. Also, each of the intermediate surface portions 130a, 130b is adjacent to the lower edge of the upper surface portions 126a, 126b respectively. The intermediate surface portions 130a, 130b each have a rounded outwardly curved outer shape.

[0065] The faceted surface 124 also includes two intermediate ends 132a, 132b. The intermediate ends 132a, 132b each have a curved outer shape. The intermediate end 132a is adjacent to the intermediate surface portion 130a. The intermediate end 132a is also adjacent to the first side 129a of the protrusion 122. The intermediate end 132b is adjacent to the intermediate surface portion 130b. The intermediate end 132b is also adjacent to the second side 129b of the protrusion 122.

[0066] The faceted surface 124 further includes two substantially flat lower surface portions 134a, 134b. The lower surface portions 134a, 134b are adjacent to each other and are symmetrically arranged about the lateral centerline of the protrusion 122. Also, the lower surface portions 134a, 134b are adjacent to the lower edges of the intermediate surface portions 130a, 130b, respectively. The lower surface portions 134a, 134b are inclined in the advancing direction of the paper stock 19 through the inlet chute 102. Also, the lower surface portions 134a, 134b are angled with respect to each other, such that the lower surface portions 134a, 134b are inclined away from each other.

[0067] The faceted surface 124 also includes two lower ends 136a, 136b. The lower ends 136a, 136b each have a curved outer shape. The lower end 136a is adjacent to the lower surface portion 134a. The lower end 136a is also adjacent to the first side 129a of the protrusion 122. The lower end 136b is adjacent to the lower surface portion 134b. The lower end 136b is also adjacent to the second side 129b of the protrusion 122.

[0068] The central portion of the stock material 19 aligned with the protrusion 122 passes over the facet surface 124 and is bent by the facet surface when the stock material 19 is drawn into the inlet chute 102 from the supply station 13. In particular, the portion located at the center of the stock material 19 passes over the lower surface portions 134a, 134b and the lower end portions 136a, 136b in a substantially flat state. Then, this portion passes over the intermediate surface portions 130a, 130b and the intermediate end portions 132a, 132b, and the direction thereof is changed by the curved outer shape of the intermediate surface portions 130a, 130b and the intermediate end portions 132a, 132b. This change in direction bends the stock material 19. The portion located at the center of the stock material 19 then returns to a substantially flat state as it is drawn onto the upper surface portions 126a, 126b and the upper end portions 128a, 128b. When the stock material 19 is bent in this way, the stock material 19 becomes more flexible when being converted into dunnage by the dunnage converter 60.

[0069] As shown in FIG. 19, the stock material 19 is then drawn onto the curved lip 140 that defines the leading edge of the bottom panel 114 and then enters the passage 120 in the inlet chute 102. Then, the stock material 19 is drawn onto the substantially flat surface 142 of the bottom panel 114. As described above, the side panels 110 are inclined inwardly such that the width of the passage 120 decreases between the inlet 116 and the outlet 118 of the inlet chute 102. This decrease in width, combined with the increased flexibility of the stock material 19 due to the bending of the stock material 19 on the protrusion 122, causes a decrease in the width of the stock material 19, whereby the stock material 19 becomes crumpled along its length, forming creases, thereby generating a continuous length of dunnage 15.

[0070] In another embodiment, the facet surface 124 can have a shape other than the specific shape described herein. In other alternative embodiments, a non-facet surface can be used in place of the facet surface 124.

[0071] As used herein, the term "substantially flat surface" can refer to a surface that appears to be completely flat and smooth. For example, a "substantially flat surface" can be a completely flat surface. Also, a "substantially flat surface" can be a surface having a large radius of curvature, e.g., 10 feet or more.

[0072] The dunnage converter 60 includes a frame 178, a first roller 180, and a second roller 182. The dunnage converter 60 also includes a drive motor (not shown) housed within a motor housing 186 and supported by the frame 178.

[0073] The stock material 19 passes between the first roller 180 and the second roller 182 and moves along a material path A. The second roller 182 is in an idling state, i.e., not directly driven by a motor. The second roller 182 is spring-biased toward the first roller 180, such that the stack material 19 is sandwiched between the first roller 180 and the second roller 182, and the resulting friction between the rotating first roller 180 and the stack material 19 moves the stack material 19 along the material path. Also, the pressure applied to the stack material 19 by the first roller 180 and the second roller 182 forms a crease in the stock material along the crease formed at the inlet 100. The drive motor is reversible so that it can reverse the direction of movement of the stack material 19 through the dunnage converter 60.

[0074] An alternative embodiment of the system 10 can include an apparatus that uses hardware other than a roll, e.g., a paper crumpler, to convert the stock material 19 into dunnage 15.

[0075] Referring to FIGS. 3-6 and FIGS. 14-17, the dunnage converter 60 also includes a cutting mechanism 200 having a cutting device in the form of a blade 202 and a housing 204. The housing 204 is coupled to the frame 178 and supports the blade 202. The blade 202 has a serrated cutting edge 206 as shown in FIG. 6. The cutting edge 206 can have other shapes in other embodiments. The blade 202 is inclined in the direction of the material path A.

[0076] In another embodiment, the cutting device can have a configuration other than the blade 202. For example, the cutting device can be configured as a wire, a knife, or another type of cutting provision in another embodiment.

[0077] The cutting mechanism 200 also includes a duckbill or hood 208. The first end of the hood 208 is coupled to the frame 178 by a pin or other suitable means such that the hood 208 can pivot relative to the frame 178 and the blade 202 between a lowered or closed position shown in FIGS. 4, 14, and 16 and a raised or open position shown in FIGS. 3, 5, 6, 15, and 17.

[0078] A second roller 182 is mounted to rotate on the hood 208. The second roller 182 is located on the hood 208 and is positioned on the hood 208 such that the second roller 182 contacts the first roller 180 when the hood is in the closed position. The user can load the stock material 19 into the dunnage converter 60 by lifting the hood 208 to the open position, placing the tip of the stock material 19 on the first roller 180, and then lowering the hood 208 to the closed position such that the stock material 19 is sandwiched between the first roller 180 and the second roller 182.

[0079] The cutting mechanism 200 further includes a grip 222. The end of the grip 222 is coupled to the freestanding end of the hood 208 by a pin or other suitable means, enabling the grip 222 to rotate between an upper or open position and a lower or closed position.

[0080] The cutting mechanism 200 also includes a drive mechanism 224 attached to the hood 208. The drive mechanism 224 is shown in FIGS. 16 and 17. The drive mechanism 224 is configured to move the grip 222 between an open position and a closed position. The drive mechanism 224 includes a drive motor (not shown), a first sprocket 226 directly driven by the drive motor, a second sprocket 228 connected to a pin that couples the grip 222 to the hood 208, and a link mechanism 229 that transmits the torque applied to the first sprocket 226 by the drive motor to the second sprocket 228. The second sprocket 228 rotates the hood 208 between a closed position and an open position. This particular configuration for the drive mechanism 224 is described for illustrative purposes only. Other embodiments can include drive mechanisms having other configurations.

[0081] 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 converter 60. The sensor 220 can be, for example, an optical sensor. In other embodiments, other types of sensors can be used. The sensor 220 is disposed proximate to the freestanding end of the grip 222 when the grip 222 is in the closed position. The sensor 220 is configured to detect the presence of dunnage 15 proximate to the sensor 220.

[0082] The cutting mechanism 200 further includes one or more bumpers 230. The bumpers 230 can be seen in FIGS. 4, 5, and 12. The bumper 230 is attached on the inward surface of the grip 222, at or near the self-standing end of the grip 222. The bumper 230 can be configured as a plurality of small knobs or buttons protruding from the grip 222. Alternatively, the bumper 230 can be configured as one or more elongated members oriented transversely to the material path A. The grip 222, the bumper 230, and the housing 204 of the housing mechanism 200 are configured such that when the grip 222 is in the closed position, the dunnage 15 that has passed through the first roller 180 and the second roller 182 is captured between the bumper 230 and the adjacent surface of the housing 204. The bumper 230 can be formed from a material such as an elastomeric material, and generates sufficient frictional force to help hold the cut piece of dunnage 15 between the bumper 230 and the housing 204.

[0083] The dunnage converter 60 can be configured to operate in a mode where the dunnage converter 60 generates dunnage 15 of a predetermined length, which is selected by the user. The dunnage converter 60 can also operate in a mode where the user can dispense dunnage of a desired non-predetermined length by pressing a button or a foot pedal until the desired length is dispensed. In either operating mode, the cutting mechanism is configured to cut the portion of the dunnage that has passed through the blade 202. In particular, when the first roller 180 is rotated by the associated drive motor, the grip 222 is in the raised position. As described above, the stock material 19 is pulled from the supply station 13 between the first roller 180 and the second roller 182. The crease formed in the stock material 19 within the inlet 100 is creased as the stock material 19 passes through and is compressed by the first roller 180 and the second roller 182.

[0084] In response to an input from the controller of the dunnage converter 60, the drive motor is stopped when a predetermined or other desired length of dunnage 15 is dispensed, whereby the first roller 180 and the second roller 182 stop the withdrawal of the stock material 19 through the dunnage converter 60. At this point, the controller also sends an input to the drive motor of the drive mechanism 224 to activate the drive motor. When activated, the drive motor rotates the grip 222 to the lowered position. When the grip 222 is in the lowered position, the bumper 224 contacts the dunnage and biases the dunnage toward the adjacent surface of the housing 204.

[0085] Next, the controller issues a command to the drive motor to operate the drive motor in the reverse direction, i.e., in a direction opposite to the direction in which the drive motor pulls the stock material 19 and the dunnage 15 in the direction of the material path A through the first roller 108. When the grip 222 is in the closed position, the dunnage 15 is wrapped around the blade 202 angled outward. Thus, the reversal of the drive motor pulls the dunnage 15 over the cutting edge of the blade 202 and cuts a portion of the dunnage 15 downstream of the blade 202.

[0086] The bumper 230 is biased toward the housing 204 by the drive mechanism 224. Thus, the cut portion of the dunnage is held in place by the bumper 230 and the adjacent surface of the housing 204. Also, a sensor 220 disposed proximate to the location where the piece of dunnage 15 is held records the presence of the dunnage 15 and generates an output that is interpreted by the controller as indicating that the piece of dunnage 15 is held by the grip 222. The controller does not initiate, or cause to be initiated, another cycle, i.e., the production of another piece of dunnage 15, until the sensor 220 indicates that the cut piece of dunnage 15 is no longer held by the grip 222.

[0087] The user can remove the debris 15 by gripping the debris and applying sufficient force to pull the debris out from between the bumper 230 and the housing 204. When the debris of the debris 15 is removed from the field of view of the sensor 220, the sensor 220 records the absence of the debris 15 and generates an output that is interpreted by the controller as an indication that the gripper 222 has stopped holding the debris 15. In response, the controller sends an input to the motor of the drive mechanism 224, whereby the motor rotates the gripper 222 to the raised position. If the debris converter 60 is operating in a mode where the next debris 15 is automatically manufactured when the previous debris is removed, the controller activates the drive motor to start the manufacturing cycle of another debris 15. If the debris converter is operating in a mode where the next debris 15 is generated upon receipt of a user input, the controller starts the next generation cycle upon receipt of the user input.

[0088] Conditional language such as "can", "could", "might", or "may", unless specifically stated otherwise or understood otherwise within the context in which it is used, is generally intended to convey that a particular feature, element, and / or action can be included in a particular implementation, but may not be included in other implementations. Thus, such conditional language is generally not intended to imply that a feature, element, and / or method is required in any way for one or more implementations, or that these features, elements, and / or methods are included in or performed by any particular implementation.

[0089] It will be apparent that many variations and other implementations of the disclosure described herein will benefit from the teachings presented in the foregoing description and related drawings. Accordingly, it is to be understood that the disclosure should not be limited to the specific implementations disclosed, and that variations and other implementations are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used for the purpose of generality and explanation only and not for limitation.

Claims

1. A drive mechanism configured to deform stock material into a continuous length dunnage, A dunnage converter including a cutting mechanism, The aforementioned cutting mechanism is A cutting device configured to cut dunnage pieces from the aforementioned continuous length of dunnage, A housing configured to support the cutting device, A grip configured to move between a first position and a second position, The grip, in the first position, applies sufficient force to the dunnage piece to hold the dunnage piece against the adjacent surface of the housing in order to hold the dunnage piece. The force is small enough to allow the dunnage piece to be pulled out of the dunnage converter while the grip is in the first position. The grip is a dunnage converter that releases the dunnage piece at the second position.

2. The dunnage converter according to claim 1, wherein the drive mechanism includes one or more rollers configured to deform the stock material as the stock material passes between the rollers.

3. The dunnage converter according to claim 1, wherein the cutting device includes a blade.

4. The dunnage converter according to claim 1, wherein the force is small enough to allow the dunnage piece to be pulled out of the dunnage converter without tearing it when the grip is in the first position.

5. Further comprising a controller, The aforementioned cutting mechanism is A sensor that is communicatively coupled to the controller and configured to detect the presence of the dunnage piece within the sensor's sensing area, The present invention further includes a drive mechanism that is communicatively coupled to the controller and configured to move the grip between a first position and a second position, The controller is configured to generate a first output in response to the removal of the dunnage piece from the sensing area of ​​the sensor. The dunnage converter according to claim 1, wherein the drive mechanism is configured to move the grip from a first position to a second position in response to the first output.

6. The dunnage converter according to claim 1, wherein the force applied to the dunnage piece is sufficient to prevent the dunnage piece from falling from the dunnage converter due to gravity.

7. The dunnage converter according to claim 1, wherein the cutting mechanism further includes a bumper mounted on the grip and configured to contact and hold the dunnage piece by the force applied to the dunnage piece.

8. The dunnage converter according to claim 7, wherein the bumper includes one or more of the following: a knob protruding from the grip, a button protruding from the grip, and an elongated member oriented laterally with respect to the material path of the dunnage passing through the cutting mechanism.

9. The drive mechanism further includes at least one roller configured to supply the continuous length dunnage to the cutting mechanism in a first direction, The dunnage converter according to claim 5, wherein the drive mechanism is further configured to reverse the direction of rotation of at least one roller while the grip is in the first position in response to an input from the controller, so that the drive mechanism pulls the continuous length dunnage in a second direction opposite to the first direction, causing the cutting device to cut the dunnage pieces from the continuous length dunnage.

10. The dunnage converter according to claim 9, wherein the grip is further configured such that the force applied by the grip when the drive mechanism pulls the continuous length dunnage in the second direction prevents the continuous length dunnage from moving in the second direction.

11. The cutting device is a blade, The dunnage converter according to claim 9, wherein the grip is configured to wrap the continuous length of dunnage around the blade.

12. The dunnage converter according to claim 7, wherein the outer surface of the bumper includes an adhesive material.

13. The dunnage converter according to claim 7, wherein the bumper includes an elastomer material.

14. The controller is configured to generate a second output when the sensor detects that the dunnage piece is within the sensing area of ​​the sensor, The dunnage converter according to claim 5, wherein the drive mechanism is configured to maintain the grip in the first position in response to the second output.

15. The dunnage converter according to claim 3, wherein the grip is positioned and configured to hold the cut dunnage piece downstream of the blade in the cutting device.

16. Includes an intake configured to supply the stock material to the dunnage converter, The aforementioned intake opening is, An inlet chute connected to the aforementioned dunnage converter, Includes a projection connected to the inlet chute, The dunnage converter according to claim 1, wherein the projection includes a plurality of surface portions configured to bend the stock material as the stock material passes over the surface portions.

17. An apparatus for manufacturing dunnage, A dunnage converter including a drive mechanism configured to deform stock material into dunnage, It includes an intake configured to guide the stock material to the dunnage converter, The aforementioned intake opening is, An inlet chute connected to the aforementioned dunnage converter, Includes a projection connected to the inlet chute, The projection is configured to bend the stock material as it passes over the projection.

18. The apparatus according to claim 17, wherein the projection is configured to bend the stock material about a first axis substantially parallel to the center line of the stock material.

19. The apparatus according to claim 18, wherein the projection is configured to bend the stock material about a second axis substantially perpendicular to the center line of the stock material.

20. The apparatus according to claim 17, wherein the projection includes the plurality of surface portions configured to bend the stock material as the stock material passes over the plurality of surface portions.

21. The apparatus according to claim 20, wherein the projection is positioned upstream of the inlet chute with respect to the material path of the stock material passing through the apparatus.

22. The entrance chute includes a bottom panel, The bottom panel is positioned downstream of the protrusion with respect to the material path of the stock material so that the stock material is drawn onto the bottom panel after passing over the surface portion of the protrusion. The aforementioned projection and the aforementioned bottom panel each have a width in a direction perpendicular to the material path of the stock material, The apparatus according to claim 21, wherein the maximum width of the projection is smaller than the width of the upstream end of the bottom panel.

23. The bottom panel is A curved lip defining the front edge of the bottom panel, The apparatus according to claim 22, further comprising a substantially flat surface adjacent to the curved lip.

24. The entrance chute defines a passage for the stock material, The passage has a width in a direction perpendicular to the material path of the stock material, The apparatus according to claim 22, wherein the width of the passage decreases in the downstream direction of the material path of the stock material.

25. The apparatus according to claim 17, wherein the projection is positioned centrally with respect to the width direction of the inlet chute.

26. The apparatus according to claim 20, wherein the surface portion of the projection is configured to bend the central portion of the stock material as the stock material passes over the surface portion.

27. ​​The apparatus according to claim 17, wherein the projection extends downward from the upstream end of the inlet chute.

28. The apparatus according to claim 21, wherein the projection includes a faceted surface comprising the plurality of surface portions.

29. The plurality of surface portions include an upper surface portion and an intermediate surface portion adjacent to the upper surface portion, The apparatus according to claim 28, wherein the upper portion and the intermediate surface portion are at least partially curved so as to bend the stock material as it passes over the upper portion and the intermediate surface portion.

30. The apparatus according to claim 29, wherein the plurality of surface portions further include substantially flat lower portions adjacent to the intermediate surface portions.

31. The upper portion is inclined upward in the direction of movement of the stock material along the material path, The apparatus according to claim 30, wherein the lower portion is inclined downward in the direction of movement of the stock material along the material path.

32. The upper portion includes a substantially flat first upper portion and a substantially flat second upper portion adjacent to the first upper portion, wherein the first upper portion and the second upper portion are arranged symmetrically with respect to the center line of the projection. The apparatus according to claim 30, wherein the intermediate surface portion includes a substantially flat first intermediate surface portion and a substantially flat second intermediate surface portion adjacent to the first intermediate surface portion, and the first intermediate surface portion and the second intermediate surface portion are arranged symmetrically with respect to the center line of the projection.

33. The upper portion further includes a first upper end and a second upper end, each having a curved outer shape, wherein the first upper end is adjacent to the first upper portion, and the second upper end is adjacent to the second upper portion. The apparatus according to claim 32, wherein the intermediate surface portion further includes a first intermediate end and a second intermediate end, each having a curved outer shape, the first intermediate end being adjacent to the first intermediate surface portion, and the second intermediate end being adjacent to the second intermediate surface portion.

34. The lower surface portion is A substantially flat first lower surface portion, A substantially flat second lower surface portion adjacent to the first lower surface portion, wherein the first lower surface portion and the second lower surface portion are arranged symmetrically with respect to the center line of the projection, Having a curved outer shape, a first lower end adjacent to the first lower surface portion, The apparatus according to claim 33, comprising a curved outer shape and a second lower end adjacent to the second lower surface portion.

35. The apparatus according to claim 17, wherein the dunnage converter includes one or more rollers configured to deform the stock material.

36. A system for manufacturing dunnage, The apparatus according to claim 17, A system including the supply of the aforementioned stock material.

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