DUNNAGE DEVICE, DUNNAGE CONVERSION SYSTEM, AND DUNNAGE CONVERSION METHOD

Abstract

A dunnage machine is provided that includes a conversion station and a static eliminator. The conversion station converts a continuous high-density stock material into a low-density dunnage and moves the dunnage downstream along a material path. The static eliminator is electrically grounded and contacts the dunnage to remove static charge from the material.

Description

[Technical field]

[0001] The present invention relates to the field of protective packaging systems. [Background technology]

[0002] In the context of paper-based protective packaging, stock material (such as paper stock material) is crumpled to produce dunnage. Most commonly, this type of dunnage is made by passing a nearly continuous strip of paper through a dunnage conversion machine. The dunnage conversion machine converts compact stock material, such as a roll of paper or a fanfold stack of paper, into a less dense dunnage material. The material is drawn into the conversion machine from a supply that is continuously formed or formed from individual sections connected together, such as stacked fanfold paper. The continuous strip of crumpled sheet material may be cut to a desired length to effectively fill a void within a container that holds the product. Dunnage material can be produced as needed by a packager. Summary of the Invention [Problem to be solved by the invention]

[0003] When material is removed from a supply of material, static electricity can build up on the material. For example, when a portion of material is separated from an adjacent portion of material in the supply, protons and electrons transfer between the surfaces of those portions, generating static electricity. Electrostatic charging can also occur when material is converted into dunnage. During the conversion process, as material comes into contact with and leaves parts of a dunnage machine, protons and electrons in the material transfer between the protons and electrons of the dunnage machine, generating static electricity. When a packager comes into contact with the charged dunnage, it can give the packager a static shock, causing the packager discomfort and disrupting the packaging process. A method is needed to reduce electrostatic charging from materials. [Means for solving the problem]

[0004] In an embodiment, a dunnage apparatus is provided that includes a converting station that converts a series of high density stock material into a low density dunnage and moves the dunnage downstream along a material pass. The static remover is electrically grounded and contacts the dunnage to remove static charge from the material.

[0005] The conversion station may have a frame constructed of a conductive material, and the static eliminator may be electrically connected to the frame. The static eliminator may be connected to a ground. The conversion station may discharge the dunnage at an exit along the material path, and the static eliminator may be positioned relative to the exit and contact the discharged dunnage to discharge static electricity. The static eliminator may extend laterally across the material path and be angled radially toward the exit trajectory to contact the dunnage in the material path as it is discharged. The static eliminator may include a brush having a spine and bristles extending from the spine into the material path, the bristles being generally parallel to the dunnage flow at the exit trajectory and angled in a partially downstream plane relative to the exit trajectory. The dunnage apparatus may further include a cutting member positioned downstream of the exit that feeds a downstream portion of the discharged dunnage from a portion of the dunnage still held by the conversion station. The dunnage apparatus may further include a supply station that supports the stock material in a fan folded configuration before the stock material is drawn into the converting station. The converting station may include an intake and a drive mechanism that draws the stock material from the supply station through an intake configured to constrict a path of the stock material and begin to compress the stock material into a dense form that forms the dunnage, and as the stock material is drawn from the supply station, adjacent layers of the fan folded material separate from one another and build up electrostatic charges. The drive mechanism may include drive rollers and pinch rollers configured to compress the dunnage from the intake and wrinkle the dunnage so that it better retains its dense configuration.The converting substation and the feeding station can be electrically isolated from ground. At least one of the converting or feeding stations can be constructed of a non-conductive material such that they do not discharge electrostatic charges. The dunnage device can be part of a dunnage converting system that also includes the stock material, and the dunnage device can crumple the material and form longitudinal crumples that extend in the machine direction. The bristles can be angled so that they are sufficiently resilient to move along the longitudinal creases formed by the dunnage machine.

[0006] In some embodiments, a method is provided that includes converting a series of high density stock material into low density dunnage, moving the dunnage along a material path, and contacting the dunnage with an electrically grounded static eliminator to remove static charge from the material.

[0007] The drawings illustrate one or more embodiments in accordance with the present concepts, by way of example only, and not by way of limitation, in which like reference numbers indicate the same or similar elements. [Brief description of the drawings]

[0008] [Figure 1A] 1 is a perspective view of an embodiment of a dunnage conversion system including a supply cart for holding stock material and a dunnage conversion system having a static eliminator; FIG. [Figure 1B] FIG. 1B is a rear view of the dunnage conversion system of FIG. 1A showing a schematic diagram of the electrical connections. [Figure 1C] FIG. 2 is a side view of the dunnage conversion system of FIG. 1 showing an embodiment of an electrical plug. [Diagram 2] FIG. 1B is a perspective view of the dunnage machine shown in FIG. 1A. [Figure 3A] FIG. 1B is a perspective view of the dunnage machine of FIG. 1A. [Figure 3B]FIG. 3B is an enlarged perspective view of a portion A of FIG. 3A. [Figure 4] FIG. 1B is a side view of the dunnage machine of FIG. 1A. [Figure 5A] FIG. 1B is a side view of the dunnage machine of FIG. 1A operating with the dunnage deflector in a stowed position. [Figure 5B] FIG. 1B is a side view of the dunnage machine of FIG. 1A operating with the dunnage deflector in a deflected position. [Figure 6A] FIG. 1B is an exploded perspective view of the dunnage machine of FIG. 1A. [Figure 6B] FIG. 1B is an exploded perspective view of the dunnage machine of FIG. 1A. [Figure 6C] FIG. 1B is a side view of the static control device of FIG. 1A. [Figure 7A] FIG. 1B is an enlarged perspective view of the dunnage machine of FIG. 1A. [Figure 7B] FIG. 1B is an enlarged perspective view of the dunnage machine of FIG. 1A discharging dunnage. [Figure 8A] FIG. 1B is a cross-sectional view of the dunnage machine of FIG. 1A with the pressing portion in an engaged position. [Figure 8B] FIG. 1B is a cross-sectional view of the dunnage machine of FIG. 1A with the pressing part in a released position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. patent application Ser. No. 15 / 592,646, filed May 11, 2017, and entitled DUNNAGE DEVICE WITH STATIC ELECTRIFIER, which is hereby incorporated by reference in its entirety.

[0010] A dunnage device for converting stock material into dunnage is disclosed. More particularly, the dunnage device includes a static eliminator that removes electrostatic charge from the material. The present disclosure is generally applicable to systems and devices in which stock material, such as paper stock material, is processed.

[0011] The stock material 19 may be stored in a bulk supply 18 as a roll (whether drawn from the inside or outside of the roll), wind, fanfold source, or other form. The stock material may be continuous or perforated. The dunnage apparatus includes a conversion station operable to move the stock material in a first direction, which may be a dispensing direction. The conversion station is supplied with the stock material from a repository through a drum in the dispensing direction. The stock material may be any suitable type of protective packaging material, including dunnage, void fill materials, inflatable packaging pillows, and the like. Some embodiments use a supply of paper or other fiber-based material in sheet form, and some embodiments use a supply of wound fiber material, such as rope or thread, and thermoplastic materials, such as a web of plastic material that can be used to form pillow packaging materials. The dunnage material 21 is converted from the stock material 19. Stock material 19 is provided from a bulk material supply 61 and fed through a drive mechanism 250 and a cutting edge 112 to a conversion station 202 for conversion to dunnage material 21 .

[0012] The conversion station can have a cutting mechanism, such as a cutting edge 112, operable to cut the dunnage material. In some embodiments, the cutting mechanism is used without user interaction or with limited user interaction. For example, the cutting mechanism pierces, cuts, or provides the dunnage material without a user contacting the dunnage material or with only slight contact of the dunnage material by a user. In particular, a biasing member is used to bias the dunnage material against or about the cutting member to improve the ability of the system to cut the dunnage material. In particular, a biasing member is used to bias the dunnage material against or near the cutting member to improve the ability of the system to provide the dunnage material. The biased location of the dunnage material is used in conjunction with or separate from other cutting functions, such as reversing the direction of travel of the dunnage material.

[0013] 1A, 1B, 1C, and 2, a dunnage conversion system 10 for processing stock material 19 is disclosed. According to some embodiments, the dunnage conversion system 10 includes an intake 70 that receives stock material 19 from a supply station 13 that includes a bulk supply 18. A drive mechanism 250 can draw or assist in drawing the stock material 19 into the intake 70. In some embodiments, the stock material 19 engages a shaping member 200 in front of the intake 70. The drive mechanism 250 can cooperate with an edge 112 to assist a user in cutting or providing the dunnage material 21 at a desired location.

[0014] 1A and 1B, according to some examples, the stock material 19 is allocated from a bulk supply 18. The stock material 19 may be stored as stacked fanfold material. However, as discussed above, other suitable types of supply or stock material may be used. The bulk supply 18 of stock material 19 may be stored in a supply station 13. In one example, the supply station 13 is a cart that is movable relative to the dunnage converting system 10. The cart supports a magazine 130 suitable for storing the stock material 19. In other examples, the supply station 13 is not movable relative to the dunnage converting system 10. For example, the supply station 13 may be a single magazine, basket, or other container on board or nearby the dunnage converting system 10.

[0015] Stock material 19 is fed from supply side 61 through intake 70. Stock material 19 begins to be transformed by intake 70 from high density stock material 19 to low density dunnage material 21 and is pulled through drive mechanism 250 and distributed in direction A at output side 62 of intake 70. The material may be further transformed by drive mechanism 250 with rollers or similar internal members that crumple, fold, flatten, or perform other similar methods to further compact the folds, creases, wrinkles, or other three-dimensional structures created by intake 70 into a permanent shape that produces a low density configuration of dunnage material. The stock material 19 may include continuous stock material 19 (e.g., continuously connected stacks, rolls, sheets of stock material), semi-continuous stock material 19 (e.g., separated stacks or rolls of stock material), or discontinuous stock material 19 (e.g., a single discrete or short length of stock material), and may be continuously, semi-continuously, or discontinuously fed to the dunnage conversion system 10. Multiple lengths may be daisy-chained. Furthermore, it is understood that several configurations of intake 70 for longitudinal crumpling machines may be applied, such as the intakes forming part of the conversion stations disclosed in U.S. Patent Publication Nos. 2013 / 0092716, 2012 / 0165172, 2011 / 0052875, and U.S. Patent No. 4,983,973. Examples of cross-direction crumpling machines include U.S. Patent No. 8,900,111.

[0016] In one configuration, the dunnage converting system 10 can include a support 12 for supporting the station. In one example, the support 12 includes an inlet guide 70 for guiding the sheet material into the dunnage converting system 10. The support 12 and inlet guide 70 are shown with the inlet guide 70 extending from a support post. In other embodiments, the inlet guide may be combined with a single rolled or curved elongated element that forms part of a support bar or post. The elongated element extends from a floor base configured to provide lateral stability to the converting station. In one configuration, the inlet guide 70 is a tubular member that also functions as a support member for supporting, crumpling, and guiding the stock material 19 toward the drive mechanism 250. Other inlet guide designs, such as spindles, can also be used.

[0017] According to some embodiments, the advancement mechanism is an electromechanical drive such as an electric motor 11 or similar power device. The motor 11 is connected to a power source, such as an outlet, via a power cord and is arranged and configured to drive the dunnage conversion system 10. The motor 11 is an electric motor whose operation is controlled by a user of the system, e.g., a foot pedal, switch, button, etc. In some embodiments, the motor 11 is part of a drive section, the drive section including a transmission for transmitting power from the motor 11. Alternatively, a direct drive can be utilized. The motor 11 is disposed within a housing and secured to a first side of the central housing, and the transmission is housed within the central housing and operably connected to the drive shaft of the motor 11 and the drive section, thereby transmitting power of the motor 11. Other suitable power devices can be used.

[0018] The motor 11 is mechanically connected to the drum 17, either directly or through a transmission, as shown in FIG. 2, so that the drum 17 rotates with the motor 11. In operation, the motor 11 drives the drum 17 in a dispensing direction or in a reverse direction (i.e., opposite to the dispensing direction). The drum 17 drives the dunnage along a material path, shown as arrow "A" in FIG. 1C, dispensing the dunnage material, or in the reverse direction pulling the dunnage material 21 back to the converting machine. Stock material 19 is fed onto the drum 17 from the feed side 61 of the intake 70 and moves in the dispensing direction to form the dunnage material 21 when the motor 11 is operating. Although described herein as a drum, this element of the drive mechanism may be a wheel, conveyor, belt, or other device operable to advance the raw material or dunnage material through the system.

[0019] According to some embodiments, the dunnage conversion system 10 includes a pinch portion operable to push the material as it passes through the drive mechanism 250. As an example, the pinch portion includes a pinch member such as a wheel, roller, sled, belt, multiple elements, or other similar member. In one example, the pinch portion includes a pinch wheel 14. The pinch wheel 14 is supported via a bearing or other low friction device disposed on an axial shaft disposed along the axis of the pinch wheel 14. In some embodiments, the pinch wheel can be powered and driven. The pinch wheel 14 is disposed adjacent to the drum 17 such that the material passes between the pinch wheel 14 and the drum 17. In some examples, the pinch wheel 14 has a circumferential pushing surface disposed adjacent to or in tangential contact with the surface of the drum 17. The pinch wheel 14 may be of any suitable size, shape, or configuration. Examples of pinch wheel sizes, shapes, and configurations include those described as press wheels in U.S. Patent Publication No. 2013 / 0092716. In the illustrated example, the pinch wheel 14 is engaged in a biased position relative to the drum 17 to engage and crush stock material 19 passing between the pinch wheel 14 and the drum 17 and convert the stock material 19 into dunnage material 21. The drum 17 or pinch wheel 14 is connected to a motor 11 via a transmission (e.g., a belt drive, etc.). The motor 11 rotates the drum or pinch wheel 14.

[0020] According to some embodiments, the drive mechanism 250 can include a guide operable to direct the material as it passes through the pinch. In one example, the guide can be a flange 33 mounted to the drum 17. The flange 33 can have a larger diameter than the drum 17 such that the material is retained on the drum 17 as it passes through the pinch.

[0021] The drive mechanism 250 controls the incoming dunnage material 19 in any suitable manner to advance it from the diverting device to the cutting member. For example, the pinch wheel 14 is configured to control the incoming stock material. As the high velocity incoming stock material diverges from its longitudinal direction, a portion of the stock material contacts an exposed surface of the pinch wheel, which pulls the diverging portion down onto the drum, crushing and creasing the resulting bunching material. The dunnage may be formed according to any technique, including those referred to herein or known techniques such as those disclosed in U.S. Patent Publication No. 2013 / 0092716.

[0022] According to some embodiments, the converting device 10 may be operable to change the direction of the stock material 19 as it moves through the converting device 10. For example, the stock material may be moved in a dispensing direction (i.e., from the inlet side to the dispensing side) or in a reverse direction (i.e., from the dispensing side to the feed side 61 or opposite the dispensing direction) by the combination of the motor 11 and drum 17. This ability to change direction allows the drive mechanism 250 to more easily cut the dunnage material 19 by pulling it directly against the edge 112. The stock material 19 is fed through the system and the dunnage material 21 and passes over or near the cutting edge 112 without being cut.

[0023] Preferably, the edge 112 may be curved or angled downward to provide a guide to deflect material in the out-feed segment of the path as it exits the system near and potentially around the edge 112. The cutting member 110 may be curved at an angle similar to the curvature of the drum 17, although other curvature angles may be used. It is noted that the cutting member 110 is not limited to cutting the material using a sharp blade, but may include members that break, tear, slice, or cause other cutting methods of dispensing the dunnage material 21. The cutting member 110 may also be configured to fully or partially cut the dunnage material 21.

[0024] In some embodiments, the lateral width of the cutting edge 112 is preferably at most the width of the drum 17. In other embodiments, the cutting edge 112 can have a width less than the width of the drum 17 or greater than the width of the drum 17. It is understood that in one embodiment, the cutting edge 112 is fixed, while in other embodiments, the cutting edge 112 is movable or pivotable. The edge 112 faces away from the drive. The edge 112 is preferably sufficiently configured to engage the dunnage material 21 as it is pulled back. The edge 112 can include a sharp or obtuse edge having a toothed or smooth configuration, and in other embodiments, the edge 112 can have a serrated edge with many teeth, an edge with shallow teeth, or other useful configuration. The teeth are defined by separated points with troughs disposed therebetween.

[0025] Generally, the dunnage material 21 follows material path A shown in FIG. 1C. As mentioned above, material path A has a direction in which the material 19 moves through the system. Material path A has several segments, such as a feed segment from a feed side 61 and a feedable segment 24. The dunnage material 21 at the delivery side 62 substantially follows path A to an edge A. An edge 112 provides a cut location where the dunnage material 21 is cut. Material path A can bend over the edge 112.

[0026] As mentioned above, any suitable stock material may be used. For example, the stock material may have a basis weight of at least about 20 lbs and up to about 100 lbs. An example of paper used includes 30 lb. Kraft paper. The stock material 19 includes paper stock stored in a high density configuration having a first longitudinal end and a second longitudinal end that is later converted to a lower density configuration. The stock material 19 may be a ribbon of sheet material stored in a fan-fold structure as shown in FIG. 1A or in coreless rolls. The stock material is formed or stored as a single layer or multiple layers of material. It is also understood that other types of materials, such as pulp-based virgin and recycled papers, newsprint, cellulose and starch compositions, poly or synthetic materials, of suitable thickness, weight, and dimensions may also be used. In some embodiments, the stock material includes an attachment mechanism, such as an adhesive, operable as a connecting member between adjacent portions of the stock material. Preferably, the adhesive facilitates daisy-chaining the rolls together to form a continuous stream of sheet material that can be fed to conversion station 70 .

[0027] [Static electricity eliminator] The dunnage device 20 includes a static eliminator 300 that removes static electricity from the material 19 caused by positive or negative charges building up on the surface of the material.

[0028] As material 19 is removed from the bulk supply 18 of stock material and fed into the dunnage machine 100, static electricity may be generated. For example, when portions of stock material 19 become separated from adjacent portions of material in the bulk supply 18, protons and electrons transfer between the surfaces of those portions, generating static electricity.

[0029] Electrostatic charges may also be generated when the material 19 is converted into dunnage. During the converting process, as the material 19 contacts and leaves parts of the dunnage machine 100, protons and electrons of the material 19 move between the protons and electrons of the dunnage machine 100, generating static electricity. Some parts of the dunnage machine 100 may be non-conductive. For example, the converting station 60 may be non-conductive. The feed station may be non-conductive. Additionally, parts of these systems, such as parts of the housing, the drum, the pinch wheel, the intake, etc., may be non-conductive. For example, as the material 19 is being converted, it rubs against the pinch wheel 14 and the drum 17, which may generate static electricity. Electrostatic charges may be generated especially in embodiments where the material 19 is made of a non-conductive material and contacts a surface of the converting machine that is made of a non-conductive material. For example, at least one of the pinch wheel 14 or the drum 17 may have a surface that contacts the material during the converting process and is made of a non-conductive material.

[0030] Static electricity can build up on the material 19 as excess electrons, creating a negatively charged material, or as excess protons, creating a positively charged material 19. The static eliminator 300 provides a conductive path between the dunnage material 19 and ground and operates to remove static electricity from both the negatively and positively charged material 19. The static eliminator 300 removes a sufficient amount of static electricity from the material so that a user can grab the produced dunnage without typically receiving an electric shock. In the embodiment shown in FIGS. 1A-8B, the static eliminator 300 extends into the material path of the dunnage 21 to contact and remove static electricity from the dunnage 21. The static eliminator can be positioned proximate the exit 112 of the conversion station 202 to remove static electricity from the dunnage 21 as it is discharged.

[0031] As shown in FIGS. 3A-4, the housing 104 of the converting station 202 can include a wall 110 proximate the outlet 112. The static eliminator 300 can extend from the wall 110 into the material path to contact the dunnage 21. The wall 110 can define an opening 114 for the static eliminator to extend from the interior to the exterior of the housing 104. Preferably, the static eliminator 300 is positioned upstream of the cutting member 120 to sufficiently remove static electricity from the dunnage 21 before a user grasps and cuts the dunnage 21 against the cutting member. For example, the static eliminator 300 can be positioned to sufficiently remove static electricity from a portion of the dunnage 21 before the converting station moves the portion of the dunnage 21 to the cutting member 120.

[0032] 4, the static eliminator 300 can be configured such that the dunnage 21 contacts the inside 314 of the static eliminator 300. For example, as the dunnage 21 moves through the outlet, the dunnage 21 can move smoothly against the contact side 314 of the static eliminator 300.

[0033] As shown in FIG. 4, the side 314 of the static eliminator 300 can extend downstream relative to the material path, downward relative to the material path A, and forms an angle θ with the bottom wall 110. The value of the angle θ can be 91-179 degrees, for example 100-165 degrees. Preferably, the angle θ is between 125 degrees and 145 degrees. The bottom wall 110 can extend substantially parallel to the E direction, which is the direction in which the dunnage 21 travels as it exits the conversion station 202. Thus, the contact side 314 can also extend at an angle θ with respect to the E direction.

[0034] In some embodiments, the E direction is the direction the dunnage travels at the last contact point within the conversion station. In some embodiments, the E direction is the direction the dunnage travels after being deflected from the bottom wall 110 of the conversion station. In some embodiments, the E direction is the direction of the tangent between the crumpling rollers (e.g., pinch wheel 14 and drum 17) or the direction the dunnage exits the part of the conversion station that converts the stock material or moves the dunnage from the dunnage machine.

[0035] The static eliminator 300 is configured to be in sufficient contact with the dunnage 21 to eliminate static electricity. The diverting device 202 can discharge the dunnage 21 at an exit of the exit trajectory TE along the path, and the static eliminator 300 can be positioned to contact the dunnage 21 as it moves along the path.

[0036] The dunnage machine 100 may include a dunnage deflector 400 that deflects the path of the dunnage 21. As shown in Figures 5A and 5B, respectively, the dunnage deflector 400 may be repositionable relative to the outlet between a removed position and a deflecting position. Figure 5A shows the deflector 400 in a removed position, where the deflector 400 is positioned out of the path to avoid deflecting the dunnage. Figure 5B shows the deflector 400 in a deflected position, where the deflector 400 is inserted into the path to deflect the dunnage 21 and change the trajectory of the dunnage. For example, the deflector 400 may change the path of the dunnage from an outlet trajectory TE to a deflected trajectory TD. Further details of the dunnage deflector are provided in U.S. patent application Ser. No. 15 / 592,753, filed May 11, 2017, entitled "Dunnage Device Carton Filler," which is incorporated herein by reference in its entirety.

[0037] 5A, in some cases, the static eliminator 300 contacts the dunnage 21 without interrupting the path of the dunnage 21 (e.g., without bending the path of the dunnage 21). The static eliminator 300 can be configured to contact the dunnage 21 to sufficiently remove static electricity without changing the trajectory of the dunnage 21. For example, the static eliminator 300 can be configured so that the dunnage glides smoothly over the contact surface of the static eliminator 300.

[0038] In another example, the static eliminator 300 contacts the dunnage 21 and bends the path of the dunnage 21. The static eliminator can be inserted into the path and deflect the path of the dunnage 21 from an exit trajectory to a deflected trajectory.

[0039] When both the static eliminator 300 and the deflector 400 are inserted into the path of the dunnage 21, the static eliminator 300 can deflect the dunnage path from the exit trajectory to a first deflected trajectory and the deflector 400 can deflect the dunnage path from the first deflected trajectory to a second deflected trajectory. Additionally or alternatively, the insertion of both the static eliminator and the deflector 400 in the dunnage path operates to deflect the dunnage from the exit trajectory to the deflected trajectory.

[0040] Deflection of the dunnage by one or more of the static eliminators 300 or deflectors 400 can guide the dunnage into a packaging container to facilitate the packaging process.

[0041] 1A-8B is positioned above the outlet 112, the static eliminator 300 may be positioned in any other suitable location or near the outlet within the scope of this disclosure. Also, while the embodiment of the static eliminator 300 shown in Figures 1A-8B includes a single component, the static eliminator 300 may include two, three, or any suitable number of components.

[0042] The static eliminator 300 may be constructed of any suitable conductive material. For example, the static eliminator 300 may be constructed of nylon and carbon. The static eliminator 300 may be constructed with more nylon than carbon. For example, the static eliminator 300 may be constructed of 75-85% nylon and 15-25% carbon, such as 80% nylon and 20% carbon.

[0043] 4, 6A, and 6B, a chassis ground 356 can electrically connect the static eliminator 300 to one or more conductive portions of the transfer station 202. For example, the static eliminator 300 can be electrically connected to a ground outlet 358 through the transfer station frame 102. The transfer station frame 102 can be constructed of a conductive material. Additionally or alternatively, a conductor can extend from the chassis ground 356 to the ground outlet 348.

[0044] The static eliminator 300 can be attached to the frame 102 by any suitable means to provide an electrical connection therebetween. As shown in FIGS. 6A and 6B, the static eliminator 300 can be attached to the frame 102 using one or more lugs 308 constructed of a conductive material. The mounting part 302 is configured to receive the conductive lugs 308 and the static eliminator 300 and can provide an electrical connection therebetween. The mounting part can receive the static eliminator 300 in a slot 304 in a seated arrangement. The static eliminator 300 can be placed in place in the slot 304 by any suitable means, such as frictional fit, adhesive, and / or mechanical fasteners. An external mounting part 306 can be disposed on the exterior of the housing 104 to receive the one or more lugs 308. FIG. 6B shows a corresponding part 358, e.g., a seat, provided on the interior of the right housing wall to engage the static eliminator.

[0045] 6A-6C, the illustrated embodiment shows a static eliminator 300 configured as a brush. A spine 320 extends transversely to the material path, preferably extending substantially the entirety of the path from a mounting 302 on the frame 102 to a corresponding mounting 358 on the right wall 106 of the housing 104. Preferably, the spine 320 is constructed of a conductive material. Bristles 322 extend from the spine in a downstream direction relative to the material path. Further discussion of brushes is provided below with reference to FIGS. 7A and 7B.

[0046] The static eliminator 300 can provide a conductive path between the dunnage material 19 and ground. The static eliminator 300 can be grounded to ground in various ways to provide a conductive path between the dunnage 21 and ground. In some embodiments, the static eliminator 300 is grounded to ground by electrically connecting to the conversion station 202 by a chassis ground. For example, a chassis ground 356 electrically connects the static eliminator 300 to the conversion station 202, which is grounded to ground. For example, a ground wire 350 can extend from the conversion station plug 358 (FIG. 4) to a ground prong 341, enter a ground connection 354 of the socket 352, and electrically connect to ground (FIG. 1C) via a conductor. In some embodiments, the conductor 350 that grounds the static eliminator 300 also grounds other components of the conversion station 100 (e.g., the motor 11) to ground. In some embodiments, the deflector 400 is grounded. Additionally or alternatively, the cutting edge 120 may be grounded.

[0047] The commutation station 202 may be operated by any suitable type of motor 11. The motor 11 may be operated by two or more phases of direct or alternating current. For example, the motor 11 may be a two-phase power motor having three output conductors, i.e., two conductors carrying alternating current of the same frequency but with a phase difference, and a third conductor that is a ground conductor. As another example, the motor 11 may be a three-phase power motor having four output conductors, i.e., three conductors carrying alternating current of the same frequency but with a phase difference, and a fourth conductor that is a ground conductor.

[0048] FIG 1B shows a schematic diagram of the electrical connections of the conversion station 202, including a power connection 342 and a common or ground connection 340. FIG 1C shows an embodiment of a socket 352, including a power connection 357 and a ground connection 354. If the motor 11 is a two-phase motor, two conductors 351 run from a plug 358 of the conversion station 202 to two power prongs 343 of the plug 358 and into the power connection 357 of the socket 352. And a ground wire 350 runs from the plug 358 of the conversion station 202 to a ground pin 341 of the plug and into the ground connection 354 of the socket 352.

[0049] In some embodiments, the static eliminator 300 is grounded to one or more conductive portions of the conversion station 202 (e.g., the conversion station frame 102) by a chassis ground 356 and is not grounded to earth. For example, the conductive frame 102 can act as a dissipation path for static electricity.

[0050] In embodiments in which the dunnage machine 100 includes a dunnage deflector 400, the machine 100 can be configured so that the dunnage material contacts the static eliminator 300 to sufficiently remove static electricity from the material before the material contacts and is deflected by the deflector 400. For example, the dunnage deflector 400 can be positioned downstream relative to the static eliminator 300.

[0051] The deflector 400 may be repositionable between the unloading position and the deflection position (e.g., FIGS. 5A and 5B ) by moving the deflector 400 along guides 220 that extend on the chassis ground 356. The deflector 400 may be part of a deflection member 410 that includes a base member 416, and the deflection member 410 may move smoothly above and downstream of the static eliminator 330.

[0052] The static eliminator 300 can have a variety of suitable configurations, including a bar, flexible membrane, plate, brush, or other structure that preferably does not impede the flow of dunnage 21 and preferably maintains contact with the passing dunnage as it is discharged by the dunnage machine 100. In the embodiment of Figures 1A-8B, the static eliminator 300 includes a brush having a spine 320 supporting a plurality of bristles 322 that extend downstream, for example, toward an exit trajectory.

[0053] A preferred brush configuration allows the bristles 322 to move resiliently, e.g., by bending, independently to increase or maximize conductive contact with the dunnage 21 surface, and more effectively remove static electricity from the dunnage 21. The dunnage machine 21 may be a longitudinal crimping device that crimps the material to form longitudinal wrinkles extending in the machine direction. The arrangement of the bristles 322, preferably angled in a plane that is generally generally parallel to and partially downstream of the flow of the dunnage at the exit trajectory, as well as the resiliency of the bristles 322, causes the bristles 322 to move through and possibly follow the longitudinal wrinkles formed in the dunnage by the longitudinal crimping device, such as the embodiment of Figures 2-3B.

[0054] As shown in FIGS. 8A and 8B, the conversion station 202 can have a pinch wheel 14 that is repositionable between an engaged position (FIG. 8A) and a released position (FIG. 8B). The conversion station housing 104 can have a pressing portion 227 that houses the pinch wheel 14 biased against the drum 17 to crush the stock material 19 passing between the pinch wheel 14 and the drum 17 to convert the stock material 19 into dunnage material 19. The pinch wheel 14 can be biased against the drum by magnetic engagement. For example, a first magnetic member 231 can be disposed in the pressing portion 227 to interact with a second magnetic member 230 on the lower housing portion 229. The first magnetic member 231 can be magnetically coupled to the second magnetic member 230 sufficiently to require a predetermined force that can separate the pinch wheel 14 from the drum 17 to overcome the magnetic coupling. For example, if a paper jam occurs between the pinch wheel 14 and the drum 17, a force can be generated that can separate the rollers. When the magnetic counting is overcome, the bias of the pinch wheel 14 to the drum 17 is reduced or eliminated due to the reduced magnetism, making it easier to clear the jam or open the device for servicing. Some embodiments of magnetic configurations can be found in U.S. Patent Publication No. 2012 / 0165172, entitled "Center Feed Dunnage System Feeder and Cutting Apparatus."

[0055] The static eliminator 300 can be mounted to the pressing portion 227 such that it is repositionable between an engaged position and a released position along with the pinch wheel 14. Thus, when the pressing portion 227 is in the released position, the static eliminator 300 moves to provide access to the interior of the conversion station, for example, to facilitate maintenance of the conversion station.

[0056] In embodiments in which the conversion station 202 includes a dunnage deflector 400, the deflector 400 may be attached to the pusher 227 such that it is repositionable along with the wheel 14. For example, both the static eliminator 300 and the deflector 400 may be repositionable between engaged and disengaged positions along the pinch wheel 14.

[0057] Those skilled in the art will appreciate that there are many types and sizes of dunnage that may need or be desired to be deposited or released in accordance with exemplary embodiments of the present invention. As used herein, the terms "upper," "lower," and / or other directional terms are used for convenience to describe the relative positions and / or orientations between parts of an embodiment. It is understood that certain embodiments or portions thereof may be located in other positions. Additionally, the term "about" should generally be understood to refer to both the corresponding number and a range of numbers. Additionally, all numerical ranges herein should be understood to include each whole integer within the range.

[0058] While exemplary embodiments of the 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 of the various embodiments may be used in other embodiments. For example, converters with drums may be replaced with other types of converters. It will be understood, therefore, that the appended claims are intended to cover all such modifications and embodiments that are within the spirit and scope of the invention.

Claims

1. a conversion station for converting a series of high density stock material into low density dunnage and moving said dunnage along a material path; a static eliminator that is electrically grounded and is positioned to contact the discharged dunnage and that contacts the dunnage to remove static electricity from the dunnage after it is converted into the dunnage; The dunnage device, wherein the static eliminator is configured to extend into the material path of the dunnage.

2. the conversion station includes a frame made of a conductive material; The dunnage device of claim 1 , wherein the static eliminator comprises a brush electrically connected to the frame.

3. 10. The dunnage device of claim 1, wherein the static eliminator is electrically grounded by a connection to earth ground.

4. the transfer station discharges the dunnage at an exit along the material path; The dunnage device of claim 1 , wherein the static eliminator is disposed relative to the outlet and contacts the discharged dunnage to discharge static electricity.

5. the static eliminator extends at an angle toward the direction in which the dunnage is discharged; 5. The dunnage device of claim 4, wherein the angle maintains the static eliminator in contact with the dunnage without impeding movement of the dunnage along the material path and causes the static eliminator to follow a plurality of longitudinal wrinkles formed in the dunnage.

6. further comprising a cutting member disposed downstream of the outlet for cutting a downstream portion of the discharged dunnage from a portion of the dunnage still held by the conversion station; the transfer station discharges the dunnage at an exit along the material path; the static eliminator is positioned relative to the outlet for contacting the discharged dunnage to discharge static electricity; 5. The dunnage apparatus of claim 4, wherein the cutting member is positioned downstream of the static electricity eliminator relative to the material path, and the transfer station sufficiently removes static electricity from the portion of the dunnage before moving the portion of the dunnage to the adjacent cutting member.

7. further comprising a feed station for supporting the stock material in a fanfold configuration before the stock material is drawn into the conversion station; 2. The dunnage device of claim 1, wherein adjacent layers of the stock material in the fanfold configuration separate from one another and accumulate the electrostatic charge as the stock material is drawn from the supply station.

8. the transfer station includes a drive mechanism that draws the stock material from a supply station through an intake configured to constrict the material path of the stock material; The dunnage device of claim 1 , wherein the drive mechanism includes a drive roller and a pinch roller configured to compress the dunnage from the inlet and crimp the dunnage so that the dunnage retains a compact configuration.

9. 10. The dunnage device of claim 1, wherein the transfer station is electrically isolated from ground.

10. 2. The dunnage device of claim 1, wherein the transfer station is constructed of a non-conductive material so as not to discharge the electrostatic charge.

11. A dunnage conversion system including the dunnage device of claim 1, the dunnage device crumples the stock material to form longitudinal wrinkles extending in the direction of the dunnage device; The dunnage conversion system, wherein the series of high density stock materials is a non-conductive paper material.

12. the static eliminator has bristles extending into the material path; the bristles are sufficiently resilient and angled to follow the longitudinal corrugations formed by the dunnage device; 12. The dunnage conversion system of claim 11, wherein the bristles are electrically grounded to remove static electricity from the dunnage.

13. The dunnage device of claim 1 , wherein the static eliminator is positioned to deflect the dunnage within the material path.

14. The dunnage device of claim 1 , wherein the static eliminator is positioned to avoid bending the path of the dunnage within the material path.

15. Convert a range of high density stock materials into low density dunnage, moving the dunnage along a material path; contacting the dunnage after it has been converted to dunnage with an electrically grounded static eliminator to remove static charge from the dunnage; The method of converting dunnage, wherein the static eliminator is configured to extend into the material path of the dunnage.

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