Dunnage device jam detector

Abstract

The dunnage manufacturing apparatus includes a jam detector mounted to a discharge chute that receives dunnage manufactured by a dunnage mechanism of the apparatus, the detector having sensitivity to detect a jam of dunnage in the discharge chute, and associated with the dunnage mechanism to cause the dunnage mechanism to stop conveyance of dunnage to the discharge chute when a jam is detected.

Description

[Technical Field]

[0001] The present disclosure relates to systems for converting paper stock and other materials into dunnage for use as packaging, and more particularly to an apparatus for detecting the presence of a paper jam in the output chute of a system for producing dunnage. [Background technology]

[0002] Paper-based protective packaging in the form of dunnage is produced by crumpling or otherwise deforming paper stock. More specifically, paper dunnage is produced by passing a generally continuous strip of paper through a dunnage machine. The continuous paper strip can be supplied, for example, from a roll or a stack of fanfold paper. The dunnage machine converts stock material into low-density dunnage material, for example, by using opposing rollers to pass the stock material between them. The rollers grip and pull the stock material from the roll or stack, deforming it as it passes between the rollers. The resulting dunnage can be cut to a desired length to effectively fill the space within a container containing the product. The dunnage material can be manufactured as needed for the person or machine performing the packaging operation. Summary of the Invention [Problem to be solved by the invention]

[0003] The ability of a dunnage machine to smoothly and continuously feed paper stock from a stack or roll is critical to its proper and efficient operation. If a jam or other obstruction occurs in the flow of paper stock feeding into the dunnage machine, the machine will not be able to produce dunnage at the required rate, which can result in delays to packaging and shipping operations that rely on the dunnage supply. Frequent jams can also lead to damage to the dunnage machine and increased maintenance costs.

[0004] Similarly, a dunnage jam in the machine discharge chute can prevent the machine from producing dunnage at the required rate, and if the jam in the discharge chute goes undetected, the dunnage machine may continue to feed dunnage down the chute despite the jam, potentially damaging the dunnage machine and the discharge chute. [Means for solving the problem]

[0005] In one aspect of the disclosed technology, an apparatus for manufacturing dunnage includes a discharge chute configured to receive dunnage and direct the dunnage to an outlet of the apparatus. The apparatus further includes a dunnage mechanism configured to transform stock material into dunnage and convey the dunnage to the discharge chute and further through the discharge chute to the outlet. The apparatus further includes a jam detector associated with the discharge chute to detect a jam of the dunnage in the discharge chute. The jam detector is associated with the dunnage mechanism and, when a jam is detected, causes the dunnage mechanism to stop conveying the dunnage to the discharge chute.

[0006] In another aspect of the disclosed technology, the jam detector includes a switch configured to be biased by the accumulation of dunnage.

[0007] In another aspect of the disclosed technology, the clog detector further includes a member having a movable surface exposed inside the discharge chute, wherein the accumulation of dunnage caused by the clog depresses the movable surface, causing the member to bias the switch.

[0008] In another aspect of the disclosed technology, the dunnage mechanism is further configured to crumple the stock material into dunnage.

[0009] In another aspect of the disclosed technology, the apparatus further includes a controller operably connected to the dunnage mechanism and the jam detector, the controller configured to control the conveyance of the dunnage.

[0010] In another aspect of the disclosed technology, the controller is further configured to inhibit operation of the dunnage mechanism when a jam is detected.

[0011] In another aspect of the disclosed technology, the discharge chute is further configured to shape the dunnage as it is directed to the outlet of the device.

[0012] In another aspect of the disclosed technology, the outlet defines an interior volume adjacent the outlet, the cross-sectional area of ​​the interior volume decreasing between the inlet and the outlet of the interior volume.

[0013] In another aspect of the disclosed technology, the width of the interior volume decreases between the inlet and outlet of the interior volume.

[0014] In another aspect of the disclosed technology, the height of the interior volume decreases between the inlet and outlet of the interior volume.

[0015] In another aspect of the disclosed technology, the apparatus further includes a separator configured to separate a portion of the dunnage from a remainder of the dunnage.

[0016] In another aspect of the disclosed technology, the separator includes a cutting mechanism.

[0017] In another aspect of the disclosed technology, the cutting mechanism includes a blade configured to cut the dunnage.

[0018] In another aspect of the disclosed technology, the member includes a flap.

[0019] In another aspect of the disclosed technology, the drive mechanism includes one or more rollers configured to transform the stock material into dunnage.

[0020] In another aspect of the disclosed technology, the apparatus further includes a gate positioned at the entrance to the discharge chute and configured to retain the portion of the dunnage after the portion of the dunnage has been separated by the separator.

[0021] In another aspect of the disclosed technology, the gate is movable between a first position in which the gate covers at least a portion of the entrance, and a second position, the gate being biased toward the first position.

[0022] In another aspect of the disclosed technology, the member is further configured to depress the movable surface by causing the dunnage within the discharge chute to move transversely relative to the length of the discharge chute.

[0023] In another aspect of the disclosed technology, a dunnage system includes a unit of stock material, a supply station configured to hold the unit of stock material, and an apparatus for manufacturing dunnage. The apparatus includes a discharge chute configured to receive the dunnage and direct the dunnage to an outlet of the apparatus, and a dunnage mechanism configured to transform the stock material into dunnage and drive the dunnage into the discharge chute and through the discharge chute to the outlet. The apparatus further includes a jam detector associated with the discharge chute to detect a jam of the dunnage in the discharge chute. The jam detector is further associated with the dunnage mechanism, and when a jam is detected, the dunnage mechanism stops conveying the dunnage into the discharge chute.

[0024] In another aspect of the disclosed technology, the stock material comprises paper. [Brief explanation of the drawings]

[0025] The following drawings illustrate certain embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. Embodiments of the present disclosure will now be described in conjunction with the accompanying drawings.

[0026] The inventive concepts are described with reference to the accompanying drawings, in which like reference numerals refer to like parts and assemblies throughout the several views. Some aspects of the inventive concepts are described below with reference to exemplary applications for illustrative purposes. It should be understood that numerous specific details, relationships, and methods are set forth to provide a thorough understanding of the inventive concepts. However, one skilled in the relevant art will readily appreciate that the inventive concepts can be practiced without one or more of these specific details, or using other methods. Additionally, well-known structures or operations have not been shown in detail to avoid obscuring the inventive concepts.

[0027] [Figure 1] FIG. 1 is a top front perspective view of a system for producing dunnage. [Figure 2] FIG. 2 is a top front perspective view of the dunnage machine of the system shown in FIG. 1 with the dunnage machine housing and discharge chute removed. [Figure 3] 3 is a top front perspective view of the dunnage machine shown in FIG. 2 with the dunnage machine housing, discharge chute, cutoff motor assembly, and cover removed. [Figure 4] FIG. 4 is a front view of the dunnage machine shown in FIGS. 1-3 with the dunnage machine housing, discharge chute, cutoff motor assembly, and cover removed and the cutoff mechanism in its home position. [Figure 5] FIG. 5 is a front view of the dunnage machine shown in FIGS. 1 to 4 with the dunnage machine housing, discharge chute, cutoff motor assembly, and cover removed and the cutoff mechanism in an intermediate position. [Figure 6] FIG. 6 is a front view of the dunnage machine shown in FIGS. 1 to 5 with the dunnage machine housing, discharge chute, cutoff motor assembly, and cover removed and the cutoff mechanism in an end position. [Figure 7]15 is a top cross-sectional view of the system shown in FIG. 1 taken along line "VII-VII" of FIG. 15, showing the flap of the paper jam detection device in an inward position indicating that there is no paper jam in the discharge chute. [Figure 8] 15 is a top cross-sectional view of the system shown in FIG. 1 taken along line "VII-VII" of FIG. 15, showing a flap of the system's paper jam detection device in an outward position indicating the presence of a paper jam in the system's discharge chute. [Figure 9] FIG. 8 is an enlarged view of a portion of FIG. 7 showing the dunnage jammed in the discharge chute. [Figure 10] 10 is a perspective view of a flap of the paper jam detector shown in FIGS. 7 to 9, showing the upstream end and backside of the flap; FIG. [Figure 11] FIG. 11 is a perspective view of the flap shown in FIG. 10, showing the upstream end and inward-facing surface of the flap. [Figure 12] FIG. 2 is a perspective view of the discharge chute of the system shown in FIG. 1, showing the upstream end of the discharge chute. [Figure 13] 2 is a perspective view of the system shown in FIG. 1 taken from the downstream side of the system, showing the discharge chute removed, the discharge chute gate in the closed position, and the flap in the facing position. [Figure 14] FIG. 14 is a perspective view from the downstream side of the system shown in FIGS. 1 and 13, showing the interior of the discharge chute. [Figure 15] 15 is a side perspective view of the system shown in FIGS. 1, 13, and 14 taken along line "XV-XV" in FIG. 8, showing the discharge chute gate in a closed position. [Figure 16] 15 taken along line "XV-XV" of FIG. 8, showing the discharge chute in an open position and holding a portion of the dunnage. [Figure 17] 17 is a cross-sectional view of the system shown in FIGS. 1 and 13 to 16 taken along line "XVII-XVII" of FIG. 8. [Figure 18]18 is a top cross-sectional view of the system shown in FIGS. 1 and 13 through 17 taken along line "XVIII-XVIII" in FIG. 15, showing the discharge chute gate in a closed position. [Figure 19] FIG. 15 is a top cross-sectional view of the system shown in FIGS. 1 and 13 to 18 taken along line "VII-VII" in FIG. 15, showing the flap of the paper jam detection device in an inward position and the gate of the discharge chute in a closed position. DETAILED DESCRIPTION OF THE INVENTION

[0028] In the following discussion, conventional features of the disclosed technology that would be apparent to one skilled in the art are omitted or only briefly described. Reference to various embodiments does not limit the scope of the claims appended hereto. In addition, any examples described herein are intended to be non-limiting and merely set forth some of the many possible embodiments for the appended claims. Furthermore, specific features described herein can be used in combination with other described features in each of a variety of possible combinations and permutations. Those skilled in the art will know how to use their instant invention, in combination with routine experimentation, to achieve other results not specifically disclosed in the examples or embodiments.

[0029] Unless otherwise defined herein, all terms are to be interpreted in the broadest possible sense, including the meaning implied by the specification and understood by those skilled in the art, and / or as defined in dictionaries, specialized texts, etc. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art of the disclosed technology. It should also be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless otherwise specified, and that, as used herein, the terms "includes" and / or "including" identify the presence of stated features, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, configurations, and / or groups thereof. Furthermore, methods, apparatuses, and materials similar or equivalent to those described herein can also be used in the practice or testing of the disclosed technology.

[0030] Throughout this disclosure, various examples of the disclosed technology are provided. The use of these examples is illustrative only and in no way limits the scope and meaning of the invention or the forms exemplified. Likewise, the invention is not limited to the specific preferred embodiments described herein. Indeed, modifications and variations of the invention will be apparent to those skilled in the art upon reading this specification and may be made without departing from its spirit and scope. Accordingly, the present invention is limited only by the terms of the claims, along with the full range of equivalents to which such claims are entitled.

[0031] As used herein, certain relationships between suppressor features are described 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 does not exclude functionally similar variations. Unless otherwise indicated by context or description, the use of the terms "substantially" or "substantially equal" in connection with two or more stated dimensions indicates that the equal relationship between the dimensions includes variations that do not alter the least significant digit of the dimension using mathematical and engineering principles recognized 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 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.

[0032] A system for converting high-density stock material into low-density dunnage is disclosed. The stock material can be formed on a vertical crimping machine, which creases the stock material longitudinally to form the dunnage, or a horizontal crimping machine, which creases the stock material transversely. The stock material supply unit can be stored in a roll (whether drawn from the inside or outside of the roll), a coiled or fan-folded supply, or other suitable form. The stock material can be continuous or perforated. The converting device feeds the stock material from the supply unit in a first direction, which can be an anti-run direction.

[0033] The stock material may be any suitable type of protective packaging material, including, for example, flat or rolled paper stock, other dunnage and void-fill materials, inflatable packaging pillows, etc. In some embodiments, a source of other paper or fibrous material in sheet form may be used. In other embodiments, a source of rolled fibrous material, such as rope or thread, may be used. In other embodiments, a thermoplastic material, such as a web of plastic material, may be used to form pillow packaging material. Examples of papers that may be used include concertina-folded supply units having stock material with 30-inch horizontal widths and / or 15-inch horizontal widths. Preferably, these sheets are concertina-folded as a single layer. In other embodiments, multiple layers of sheets may be concertina-folded together, such that dunnage is created from overlapping sheets that are crumpled together during the converting process.

[0034] 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 paper stock stored in a high-density configuration with a first longitudinal edge and a second longitudinal edge and later converted to a lower-density configuration by a dunnage system. The stock material can be a ribbon of sheet material stored in a fanfold configuration, as shown in FIG. 1, or stored as a coreless roll (not shown). The stock material can be formed or stored as a single-ply or multi-ply material. When multi-ply materials are used, a single ply can include multiple layers. Other types of materials, such as pulp-based virgin or recycled paper, newsprint, cellulose or starch compositions, polymeric or synthetic materials, and the like, having appropriate thicknesses, weights, and dimensions, can also be used.

[0035] In some embodiments, the stock material supply unit can have an accordion-like folding configuration. For example, a foldable material, such as paper, may be repeatedly folded to form a stack or a three-dimensional body. The term "three-dimensional body" refers to a material having three dimensions, all of which are not negligible, as opposed to a "two-dimensional" material. A continuous sheet, such as a sheet of paper, plastic, or foil, can be folded with multiple fold lines extending transversely to the longitudinal direction of the continuous sheet or the feed direction of the sheet. For example, folding a continuous sheet having a substantially uniform width along transverse fold lines can form or define sheet sections having approximately the same width. Sequential folding of the continuous sheet in opposite or alternating directions can produce an accordion-like continuous sheet. For example, folds can form or define sections along the continuous sheet, and the sections can be substantially rectangular.

[0036] 1 illustrates one embodiment of an apparatus 10 for manufacturing dunnage. The apparatus 10 is configured to convert stock material 19 into dunnage 15. The apparatus 10 includes a supply unit 18 for the stock material 19 and a dunnage apparatus 50.

[0037] Apparatus 10 also includes apparatus 400 for detecting the presence of a jam of paper dunnage 15 in discharge chute 62 of apparatus 10. Apparatus 400 is described, for purposes of example only, in conjunction with supply unit 18 and dunnage apparatus 50. Apparatus 400 may be used in conjunction with dunnage apparatuses having different configurations than dunnage apparatus 50, and supply units 18 having different configurations than supply unit 18.

[0038] The dunnage apparatus 50 includes a dunnage machine 60 , a support 12 configured to support the dunnage machine 60 , and a supply station 13 configured to hold a supply unit 18 of stock material 19 .

[0039] The particular configuration of the support 12 shown in the figures is disclosed for illustrative purposes only. The support 12 can have other configurations suitable for supporting the dunnage machine 60.

[0040] Similarly, the shelf or basket-type configuration of supply station 13 shown in FIG. 1 for accommodating supply units 18 in the form of stacks of folded stock material 19 is disclosed for illustrative purposes only. Supply station 13 can have other configurations suitable for supporting supply units 18 in single bundles, multiple stringed bundles, flat configurations, rolled configurations, and / or curved configurations.

[0041] The feed station 13 can support one or more feed units 18 of stock material 19. In applications where multiple feed units 18 are accommodated in the feed station 13, the end and start sheets of adjacent feed units 18 are connected to one another either before or after being placed at the feed station 13. By connecting or daisy-chaining multiple feed units, a continuous supply of stock material 19 can be provided.

[0042] Stock material 19 is converted into dunnage 15 by following material path A through apparatus 10, as shown in Figure 1. Material path A has an inlet end where stock material 19 is fed into apparatus 10 and a discharge end where dunnage 15 exits apparatus 10.

[0043] 1-6 show the dunnage machine 60 of the apparatus 10. The dunnage machine 60 includes a housing 61, an intake 100, a cut motor assembly 201, and a feed motor 305.

[0044] For ease of illustration, Figures 2 and 3 show dunnage machine 60 with housing 61 removed, thus exposing frame 63 and a separator in the form of cutting mechanism 200 of dunnage machine 60. Intake 100 is rotatably coupled to frame 63 via a suction spindle (not shown). Intake 100 can be rotated upwardly about the suction spindle from a closed or lowered position, as shown in Figure 1, to a raised or open position (not shown). The ability to rotate intake 100 upward in this manner allows a user to clear stuck or obstructed material from the outlet portion of intake 100.

[0045] The dunnage machine 60 also includes a drive assembly 300, which is visible in Figures 7, 8, 15, and 16. The drive assembly 300 includes a feed motor 305 (shown schematically in Figure 15) and rollers 310, 320. The rollers 310, 320 are configured to drive the stock material 19 through the dunnage machine 60, convert the stock material 19 into dunnage 15, and push the dunnage 15 out the discharge chute 62.

[0046] Inlet 100 includes a guide having an inlet end for receiving stock material 19 from supply unit 18 and a discharge end that travels within inlet 100 along a portion of material path A and through which stock material 19 passes as it exits inlet 100. Jam detection device 400 can be used as part of a dunnage manufacturing system with inlets having configurations different from the one shown.

[0047] 7, 8, 15, and 16 illustrate rollers 310 and 320. Rollers 310 and 320 are configured to compress and crumple stock material 19 entering dunnage machine 60, convert the stock material 19 into dunnage 15, and transport the dunnage 15 through and out of dunnage machine 60. In particular, rollers 310 and 320 are configured to draw stock material 19 from inlet supply 18 through intake 100, crumple or otherwise deform the stock material 19 as it passes between rollers 310 and 320, and then push the newly formed dunnage 15 downstream through cutting mechanism 200 and into discharge chute 62. Details of rollers 310 and 320 are provided for illustrative purposes only. Jam detection device 400 can be used in conjunction with rollers having other configurations and dunnage machines that crumple and deform stock material 19 using means other than rollers.

[0048] Roller 320 is driven to rotate by feed motor 305. Roller 310 is idle, i.e., roller 310 is not driven by a motor. Roller 310 is biased toward roller 320 and is driven to rotate by interaction with the rotating roller 320 via the outer circumferential surface of roller 310. In an alternative embodiment, roller 310 may be driven by the motor of drive assembly 300.

[0049] The outer circumferential surface of roller 310 is substantially smooth. Roller 320 has a different shape or contour than roller 310. For example, the outer circumferential surface of roller 320 may be formed with a groove that receives a toroidal ridge (not shown).

[0050] During operation of the dunnage machine 60, stock material 19 is drawn by rollers 310, 320 from the supply station 13 through the inlet 100 and into between the rollers 310, 320. The ridges of roller 320 and the opposing circumferential surface of roller 310 exert pressure on the stock material 19. This pressure crumples or otherwise deforms the stock material 19, increasing the volume of the stock material 19 and converting the stock material 19 into dunnage.

[0051] 2 and 3 show the cutting mechanism 200 of the dunnage machine 60 coupled to the frame 63. For clarity, Figures 2 and 3 show the dunnage machine 60 without the housing 61. The cutting mechanism 200 includes a cutter motor assembly 201 having a cutter motor 202, a cover 210, a crank, a shuttle 230, a magnet 203, a cutting portion 220, and an anvil portion 240.

[0052] The crank includes a crank arm 204 that is rotated by the cutoff motor assembly 201. As can be seen in Figures 2-6, the shuttle 230 has a guide slot 231 formed therein and configured to receive an end of the crank arm 204, thereby allowing the crank arm 204 to translate between the ends of the guide slot 231 as the crank rotates. The engagement of the rotating crank arm 204 with the shuttle 230 imparts linear motion to the shuttle 230 in the cutting direction B.

[0053] The cover 210 defines a recess configured to receive the crank and a space within the cover 210 for receiving the shuttle 230. The shuttle 230 is configured to mate with the cutting portion 220 such that movement of the shuttle 230 imparts corresponding movement to the cutting portion 220.

[0054] The cutting portion 220 is held by a magnet 203 against an anvil portion 240, which is attached to the frame 63 and is stationary relative to the cutting portion 220. The magnet 203 allows the cutting portion 220 to slide in a cutting direction B along the contact surface of the anvil portion 240.

[0055] The cutting portion 220 has a cutting edge 223. The tip of the cutting edge 223 has a sharp tip, and the cutting edge 223 efficiently cuts the dunnage 15 and helps to secure the dunnage 15 in the center so that the dunnage 15 does not bunch up to one side. Such bunching can cause the dunnage 15 to bunch up, which can make cutting the dunnage 15 difficult.

[0056] In an assembled state, the cutting portion 220 and the anvil 242 define a window 241 through which the dunnage 15 passes after being transformed by the drive mechanism 300. The window 241 is shown in FIGS. 4, 5, and 20. The cutting mechanism 200 is movable (without stopping) from a home position (shown in FIGS. 3 and 4), through an intermediate position (shown in FIG. 5), to an end position (shown in FIG. 6) in response to rotation of the crank arm 204. In the home position, the cutting portion 220 is positioned furthest from the anvil 242, and the window 241 is at its largest size. As the cutting mechanism 200 moves toward and past the intermediate position and the cutting portion 220 moves in cutting direction B, the window 241 decreases in size. When the dunnage 15 is positioned within the window 241, as occurs during normal operation of the dunnage machine 60, the cutting edge 223 begins to cut the dunnage 15 when the cutting mechanism 200 is approximately in the intermediate position.

[0057] FIG. 6 shows the cutting mechanism 200 in its end position. The window 241 previously defined between the cutting section 220 and the anvil 242 is closed, i.e., no longer present, as the cutting section 220 moves past the anvil 242. The dunnage 15 located within the window 241 is forced against the anvil 242 and severed by the cutting section 220 as the cutting section 220 advances in cutting direction B to the position shown in FIG. 6. Thus, the portion of dunnage 15 that advanced through the window 241 following the previous cutting cycle is severed to form another piece of dunnage 15. The newly severed dunnage 15 can exit the dunnage machine 60 through the exit 65 of the discharge chute 62. As will be described below, if one or more pieces of dunnage 15 become jammed within the discharge chute 62, the jam detection device 400 detects the presence of the jam and generates an output that causes the controller 64 of the apparatus 10 to suspend operation of the dunnage machine 60 until the jam is cleared. The controller 64 is shown diagrammatically in FIG.

[0058] After the cutting mechanism 200 reaches the end position, continued rotation of the crank arm 204 will eventually return the crank arm 204 to the home position.

[0059] The details of cutting mechanism 200 are provided for illustrative purposes only. Jam detection device 400 can be used in combination with other types of separators, in combination with cutting mechanisms having configurations other than that of cutting mechanism 200, and in combination with dunnage devices in which the dunnage is severed by means other than cutting, such as by tearing or the focused application of heat.

[0060] Additional details of the supply unit 18 and dunnage device 50 are provided in U.S. Application No. 18 / 340,805, the contents of which are incorporated herein by reference in their entirety.

[0061] The system 110 further includes an optical sensor 25. The optical sensor 25 is shown in FIG. 16. The optical sensor 25 is mounted to the discharge chute 62 and optically coupled to the interior volume 410 of the discharge chute 62 via the aperture 26 therein, thereby enabling the sensor 25 to detect the presence or absence of dunnage 15 within the interior volume 410. The sensor 25 is communicatively connected to the controller 64. When the sensor 25 indicates that no dunnage piece 15 is present within the discharge chute 62, the controller 64 is configured to activate the drive assembly 300 and the cutting mechanism 200 to produce another dunnage piece 15 in the manner described above, thereby allowing for continued availability of dunnage 15. When the controller 64 receives input from the sensor 25 indicating that a dunnage piece 15 is present within the discharge chute 62, the controller 64 maintains the drive assembly 300 and the cutting mechanism 200 in an inactive state. Alternative embodiments of the apparatus 10 may be configured without the sensor 25. For example, such a system may be manually activated and may continuously produce dunnage strips 15 while activated.

[0062] The jam detection device 400 is incorporated into the discharge chute 62. The discharge chute 62 is mounted to the dunnage machine 60 downstream of the cutting mechanism 200. The discharge chute 62 has a forward or upstream end that defines an entrance to the discharge chute 62. The entrance is aligned with a window 241 defined by the cutting portion 220 and anvil 242 of the cutting mechanism 200. The entrance receives the paper dunnage 15 after it has been converted by the drive mechanism 300 and allows the dunnage 15 to pass into the interior volume 410 of the discharge chute 62. When the dunnage 15 is cut by the cutting mechanism 200 as described above, the resulting dunnage pieces 15 located within the interior volume 410 can be extracted or pulled from the discharge chute 62 by a user or an automated mechanism through an exit 65 defined by the downstream end of the discharge chute 62.

[0063] As will be described below, if one or more pieces of dunnage 15 become jammed in the discharge chute 62, the jam detection device 400 will detect the presence of the jam and, when received by the controller 64, will generate an output that will cause the operation of the dunnage machine 60 to be stopped until the jam is cleared.

[0064] 7-11, the clog detection device 400 includes a movable member in the form of a plate or flap 402. The flap 402 is located within an interior volume 410 of the discharge chute 62. As can be seen in FIGS. 9 and 14, the flap 402 is rotatably mounted to the top and bottom walls 34, 36 of the discharge chute 62 by pins 418. The flap 402 is positioned adjacent to a side wall 403 of the discharge chute 62. In alternative embodiments, the flap 402 can be coupled to the discharge chute 62 using other mounting configurations.

[0065] The flap 402 includes a body 404. The body 404 has a substantially flat major surface 406 that faces inward toward the centerline of the discharge chute 62. The body 404 also has an upper end 408 and a lower end 410, respectively, adjacent the major surface 406. The upper end 408 and the lower end 410 are angled downward as they extend downstream to match the downward angle of the adjacent surfaces of the discharge chute 62.

[0066] Body 404 further includes an upstream end 412 and a downstream end 414, each adjacent major surface 406. Upstream end 412 and downstream end 414 each have a substantially vertical orientation.

[0067] Flap 402 is configured to rotate relative to sidewall 403 between a first or inward position, shown in Figure 8, and a second or outward position, shown in Figures 7 and 9. With reference to Figures 7 through 9, the upstream end of flap 402 is spaced a distance 407 from the opposite wall of discharge chute 62. Distance 407 when flap 402 is in its inward position is less than distance 407 when flap 402 is in its outward position.

[0068] As can be seen in FIG. 10 , the flap 402 includes two knuckles 416 adjacent the downstream end 414 of the body 404. The knuckles 416 are configured to receive the pins 418 with minimal clearance so that the flap 402 can rotate smoothly on the pins 418. Ends of the pins 418 are received in respective holes 419 formed in the upper and lower walls 34, 36 of the discharge chute 62. The ends of the pins 418 can be retained in the holes 419 by an interference fit or other suitable means. One of the holes 419 is visible in FIG. 12 . The pins 418 have a substantially vertical orientation when attached to the discharge chute 62 so that the axis of rotation of the flap 402 is substantially vertical.

[0069] As can be seen in FIG. 12 , recesses 420 are formed in each of the upper and lower walls 34, 36 of the discharge chute 62. The recesses 420 face inward toward the interior volume 410 of the discharge chute 62 and accommodate the body 404 of the flap 402 as the flap 402 rotates relative to the discharge chute 62. The upper and lower portions of the body 404 are captured between the side walls 403 of the discharge chute 62 and the longitudinal ends of the respective recesses 420. Additionally, the upper end 408 and lower end 410 of the body 404 are positioned within the respective recesses 420 in the upper and lower walls 34, 36, thereby helping to prevent the dunnage 15 from getting caught or entangled between the upper end 408 and lower end 410 and the adjacent surfaces of the discharge chute 62.

[0070] The range of rotation of the flap 402 may be, for example, approximately 4.5°. This specific value is provided for illustrative purposes only, and the range of rotation of the flap 402 may be greater than or less than approximately 4.5° in alternative embodiments.

[0071] The disclosure of the flap 402 as the movable member is for purposes of example only, as the movable member can have other shapes and configurations in alternative embodiments.

[0072] The device 400 also includes a switch or sensor 422 attached to the flap 402. The sensor 422 is electrically connected to the controller 64. The sensor 422 is attached to the rear or back surface 424 of the main body 404 of the flap 402, as can be seen in FIGS. 7 and 8. The back surface 424 is located opposite the main surface 406 of the main body 404. The flap 402 further includes two brackets 426 extending from the back surface 424, as shown in FIG. 10. The brackets 426 are spaced apart and define a space for receiving the sensor 422. The sensor 422 can be securely fitted into the brackets 426. In alternative embodiments, the sensor 422 may be secured to the flap 402 by other means, such as a fastener.

[0073] 7-9, the sensor 422 includes a body 428 and an arm 430. The arm 430 is coupled to the body 428. The arm 430 is configured to rotate relative to the body 428 between a first or open position, shown in FIG. 8, and a second or closed position, shown in FIGS. 7 and 9. The sensor 422 further includes a spring (not shown) disposed within the body 428 and configured to bias the arm 430 toward its first or open position. The bias of the arm 430 created by the spring also biases the flap 402 toward its first or inward position. In an alternative embodiment, a separate spring may be included to bias the flap 402 toward its inward position.

[0074] Sensor 422 further includes a throw and contacts (not shown) disposed within body 428. The throw is connected to arm 430. When arm 430 is in its open position, the throw is spaced apart from the contacts. When arm 430 is moved to its closed position, the throw makes physical contact with the contacts, thereby establishing electrical contact between the throw and the contacts. The electrical contact between the throw and the contacts when arm 430 is in its closed position causes sensor 422 to produce an electrical output that is transmitted to controller 64.

[0075] The sensor 422 is configured such that the arm 430 is in the closed position when the flap 104 is in its inward position, and the arm 430 is in the open position when the flap 104 is in its outward position. Accordingly, the controller 64 is configured to interpret a condition in which the controller 64 receives an output signal from the sensor 422 as an indication that the flap 402 is in its outward position. Conversely, the controller 64 is configured to interpret a condition in which the controller 64 does not receive an output signal from the sensor 422 as an indication that the flap 402 is in its inward position.

[0076] The sensor 422 can have configurations other than those described above. For example, the sensor 422 can be an optical sensor, a laser probe, an LVDT, an RVDT, a pressure transducer, a piezoelectric transducer, or the like.

[0077] The clog detection device 400 also includes a guide 448 mounted to the discharge chute 62 immediately upstream of the upstream end 412 of the flap 402. The guide 448 is shown in Figures 7, 8, and 19. The guide 448 and the upstream end 412 cooperate to inhibit cuttings and other debris from entering the cavity or volume defined by the underside 424 of the flap 402 and the adjacent surface of the sidewall 403 of the discharge chute 62. Allowing such debris to enter the cavity could interfere with the proper operation of the sensor 422.

[0078] The device 400 is configured to sense a paper jam in the discharge chute 62 downstream of the cutting mechanism 200 and generate an output that, when received by the controller 64, causes the controller 64 to suspend operation of the dunnage machine 60 until the paper jam is cleared. More specifically, the flap 402 is biased toward its first or inward position, as described above. When the paper dunnage 15 is fed into the discharge chute 62 by the dunnage machine 60 after being cut, the lateral or side-to-side dimensions of the dunnage 15 are small enough that no forced contact occurs between the dunnage 15 and the flap 402. Thus, the flap 402 remains in its first or inward position, the arm 430 of the sensor 422 remains in its open position, the contacts between the throw and the sensor 422 remain physically and electrically out of contact, and the controller 64 interprets the absence of an electrical signal from the sensor 422 as indicating that no paper jam exists in the discharge chute 62.

[0079] If the paper dunnage 15 becomes jammed in the chute 62, continuing to feed the dunnage 15 from the dunnage machine 60 forces the dunnage 15 within the chute 62 to move laterally or in a zigzag pattern, as shown in FIG. 9 . The lateral movement of the dunnage 15 forces the dunnage 15 into contact with the inwardly facing major surface 406 of the flap 104, causing the flap 402 to rotate to a second or outward position. Rotation of the flap 402 to its outward position moves the arm 430 from its open position to its closed position, thereby establishing physical and electrical contact between the throw and contacts of the sensor 422. The resulting electrical output of the sensor 422 is received by the controller 64, which then interrupts operation of the dunnage machine 60.

[0080] The controller 64 prevents the dunnage machine 60 from restarting until the controller 64 no longer receives a signal from the sensor 422 indicating the presence of a paper jam in the discharge chute 62. When an operator clears the jam from the discharge chute 62 and the jammed paper dunnage 15 is no longer in contact with the flap 402, the inward bias on the sensor 422 on the flap 402 causes the flap 402 to return to its first or inward position, thereby removing the flap from contact with the sensor 422. At this point, the controller 64, which is no longer receiving an output signal from the sensor 422, allows the dunnage machine 60 to resume operation if the operator presses a reset button (not shown). Alternate embodiments can be configured without a reset button. The substantially flat configuration of the flap 402 and the fact that the major surface 406 of the flap 402 is substantially aligned with the normal direction of movement of the dunnage 15 through the discharge chute 62 allows an operator to pull jammed dunnage 15 from the interior volume of the discharge chute 62 without being obstructed by the jam detection device 400.

[0081] In an alternative embodiment, the apparatus 400 may be configured so that the dunnage 15 acts directly on the sensor 422. For example, the sensor 422 may be configured as a pressure or piezoelectric transducer that generates an output in response to pressure exerted directly on the sensor 422 by the jammed dunnage 15. In such an embodiment, the apparatus 400 may be configured without a moving member, such as the flap 402. In another alternative embodiment, the sensor 422 may be configured to directly interrupt the supply of power to the feed motor 305 when the sensor 422 registers the presence of a jam.

[0082] The discharge chute 62 may include a door or gate 440, shown in Figures 13-19. The gate 440 is suspended from a bracket 442 and aligns with a window 241 defined between the cutting portion 220 and the anvil 242.

[0083] Gate 440 is coupled to bracket 442 via pin 444, which allows rotation of gate 440 relative to bracket 442 and front wall 444. Gate 440 has a height or vertical dimension that is less than the height of window 241. Gate 440 is shown in Figures 13-15 and 17-19 in a closed position where gate 440 covers a portion of the entrance to discharge chute 62.

[0084] Gate 440 is biased toward the closed position by a torsion spring (not shown) disposed around pin 444. Bracket 442 is configured to limit rotation of gate 440 beyond the closed position.

[0085] As the dunnage 15 moves downstream into the discharge chute 62, the gate 440 resists the spring bias and rotates approximately 90° from its closed position toward the interior volume 410 to the open position shown in FIG. 16 . More specifically, as the dunnage 15 moves downstream, the dunnage 15 exerts a drag force on the gate 440, which increases due to the bias of the torsion spring on the gate 440. This drag force causes the gate 440 to rotate from its closed position. When in the open position, the gate 440 does not impede the passage of the dunnage 15 into the interior volume 410. Due to the spring bias, the gate 440 exerts a downward force on the dunnage 15. Once the dunnage 15 is cut by the cutting mechanism 200, the gate 440 continues to exert a force on the dunnage 15 due to its spring bias. This force acts as a clamping force to hold the dunnage 15 in place until an operator or other user pulls on the downstream end of the dunnage strip 15 to remove it for the discharge chute 62. Once the dunnage strip 15 is removed from the discharge chute 62, the gate 440 returns to the closed position under the bias of the spring.

[0086] An alternative embodiment of the discharge chute 62 may be configured without the gate 440 .

[0087] Those skilled in the art should understand that there are many types and sizes of dunnage that may need or desire to be produced, stored, and / or discharged, and that the present apparatus 400 and its alternative embodiments may be used in conjunction with alternative embodiments of the apparatus 10 configured to produce such dunnage.

[0088] As used herein, the terms "upper," "lower," and / or other directional terms are used herein for convenience and to indicate relative positions and / or orientations between parts of an embodiment. It will be understood that certain embodiments, or portions thereof, may be oriented in other positions. In addition, the term "about" should generally be understood to refer to both the corresponding numerical value and range of values. Furthermore, all numerical ranges herein should be understood to include each integer within the range.

[0089] Although specific features, functions, components, and parts have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the present disclosure that fairly fall within the scope of permissible equivalents. Also, while exemplary embodiments of the present invention are disclosed herein, it will be understood that numerous modifications and other embodiments may be devised by those skilled in the art. For example, features described for various embodiments can be used in other embodiments, and the appended claims are intended to cover all such modifications and embodiments that fall within the spirit and scope of the present invention.

[0090] In particular, conditional language such as "can," "could," "might," or "might" is generally intended to convey that certain implementations may include certain features, elements, and / or operations, while other implementations do not, unless specifically stated otherwise or understood otherwise within the context in which it is used. 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 implementations, or that these features, elements, and / or methods are included in or performed in any particular implementation.

[0091] Many modifications and other embodiments of the disclosure described herein will be apparent with the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is therefore to be understood that the disclosure is not to be limited to the particular embodiments disclosed, and that 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 in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. An apparatus for manufacturing dunnage, a discharge chute for receiving the dunnage and directing the dunnage to an outlet of the apparatus; a dunnage mechanism configured to transform stock material into the dunnage and convey the dunnage to the discharge chute and through the discharge chute to the outlet; and a jam detector associated with the discharge chute and configured to detect a jam of dunnage within the discharge chute, the jam detector further associated with the dunnage mechanism to cause the dunnage mechanism to stop conveying the dunnage to the discharge chute when the jam is detected.

2. The device of claim 1 , wherein the jam detector further comprises a switch configured to be biased by the buildup of dunnage.

3. 2. The apparatus of claim 1, wherein the jam detector further includes a member having a movable surface exposed inside the discharge chute, the buildup of dunnage caused by the jam depressing the movable surface, causing the member to bias the switch.

4. The apparatus of claim 1 , wherein the dunnage mechanism is further configured to crumple the stock material into the dunnage.

5. The apparatus of claim 1 , further comprising a controller operatively connected to the dunnage mechanism and the jam detector, the controller configured to control the conveying of the dunnage.

6. The apparatus of claim 5 , wherein the controller is further configured to inhibit operation of the dunnage mechanism when the jam is detected.

7. The apparatus of claim 1 , wherein the discharge chute is further configured to shape the dunnage as it is directed to the outlet of the apparatus.

8. the discharge chute defines an interior volume adjacent the outlet; The apparatus of claim 7 , wherein the cross-sectional area of ​​the interior volume decreases between the inlet and the outlet of the interior volume.

9. The device of claim 8 , wherein a width of the interior volume decreases between the inlet and the outlet of the interior volume.

10. The apparatus of claim 8 , wherein the height of the interior volume decreases between the inlet and the outlet of the interior volume.

11. The apparatus of claim 1 , further comprising a separator configured to separate a portion of the dunnage from a remainder of the dunnage.

12. The apparatus of claim 11 , wherein the separator includes a cutting mechanism.

13. The device of claim 12 , wherein the cutting mechanism includes a blade configured to cut the dunnage.

14. The device of claim 3 , wherein the member comprises a flap.

15. The apparatus of claim 1 , wherein the drive mechanism includes one or more rollers configured to deform the stock material into the dunnage.

16. The apparatus of claim 11 , further comprising a gate disposed at an entrance to the discharge chute and configured to retain the portion of the dunnage after the portion of the dunnage is separated by the separator.

17. the gate is movable between a first position in which the gate covers at least a portion of the entrance and a second position; 17. The apparatus of claim 16, wherein the gate is biased toward the first position.

18. The apparatus of claim 3 , wherein the member is further configured to depress the movable surface by causing the dunnage within the discharge chute to move transversely relative to the length of the discharge chute.

19. Stock material units, a supply station configured to hold units of said stock material; and an apparatus for producing dunnage, The device comprises: a discharge chute configured to receive the dunnage and direct the dunnage to an outlet of the apparatus; a dunnage mechanism configured to transform the stock material into the dunnage and convey the dunnage to the discharge chute and through the discharge chute to the outlet; and a jam detector associated with the discharge chute for detecting a jam of dunnage within the discharge chute; The dunnage system, wherein the jam detector is associated with the dunnage mechanism, and when a jam is detected, the dunnage mechanism stops conveying the dunnage into the discharge chute.

20. 20. The system of claim 19, wherein the stock material comprises paper.

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