Discharge chutes for void fill conversion machines

Abstract

A discharge chute includes an inlet side and an outlet side. The inlet side has an inlet that receives dunnage material. The outlet side has an outlet that discharges the dunnage material. The inlet and the outlet are in fluid communication through the discharge chute so that the dunnage material can pass through the discharge chute from the inlet to the outlet. The outlet has a shape that includes a slot portion, a first circular portion on a first end of the slot portion, and a second circular portion on a second end of the slot portion. A width of the slot portion is less than each of a diameter of the first circular portion and a diameter of the second circular portion.

Description

Attorney Docket No. P46183-WODISCHARGE CHUTES FOR VOID FILL CONVERSION MACHINESSPECIFICATIONBACKGROUND

[0001] The present disclosure is in the technical field of conversion machines that produce dunnage for void fill and / or cushioning. More particularly, the present disclosure is directed to discharge chutes for void fill conversion machines that have a minimal size while providing appropriate safety to users.

[0002] Machines for producing void fill material from paper are well-known in the art. Such machines generally operate by pulling a web of paper from a roll or fanfold paper, manipulating the paper web in such a way as to convert the paper into void fill material, and then cutting the converted material into cut sections of a desired length.

[0003] While such machines are widely used and have been commercially successful, in many applications, there is a need for improved functionality. For example, discharge chutes have been used with these machines dow nstream of the severing mechanism. The discharge chutes are a safety feature to avoid injuries to users of the machines from the severing mechanism. However, the size of discharge chutes can increase the footprint of the machine to an area that is larger than desired in packaging facilities.SUMMARY

[0004] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary' is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0005] In a first embodiment, a discharge chute includes an inlet side comprising an inlet configured to receive dunnage material and an outlet side comprising an outlet configured toAttorney Docket No. P46183-WO discharge the dunnage material. The inlet and the outlet are in fluid communication through the discharge chute so that the dunnage material can pass through the discharge chute from the inlet to the outlet. The outlet has a shape that includes a slot portion, a first circular portion on a first end of the slot portion, and a second circular portion on a second end of the slot portion. A width of the slot portion is less than each of a diameter of the first circular portion and a diameter of the second circular portion.

[0006] In a second embodiment, each of the diameter of the first circular portion and the diameter of the second circular portion of the first embodiment is less than or equal to 40 mm.

[0007] In a third embodiment, the width of the slot portion of the second embodiment is less than or equal to 20 mm.

[0008] In a fourth embodiment, a length of the discharge chute of the third embodiment between the inlet side and the outlet side is greater than or equal to 120 mm.

[0009] In a fifth embodiment, a centerline of the slot portion of any of the preceding embodiments is aligned with a center of the first circular portion and a center of the second circular portion.

[0010] In a sixth embodiment, a centerline of the slot portion of any of the first to fifth embodiments is offset from a center of the first circular portion and from a center of the second circular portion.

[0011] In a seventh embodiment, a distance between a center of the first circular portion and a center of the second circular portion of any of the preceding embodiments is at least 25% greater than the larger of a diameter of the first circular portion and a diameter of the second circular portion.

[0012] In an eighth embodiment, an area of the inlet of any of the preceding embodiments is greater than an area of the outlet.

[0013] In a ninth embodiment, the discharge chute of any of the preceding embodiments further includes a funneling surface between the inlet and the outlet. The funneling surface is arranged to guide the dunnage material from the inlet to the outlet as the dunnage material passes through the discharge chute.Attorney Docket No. P46183-WO

[0014] In a tenth embodiment, the dunnage material of any of the preceding embodiments is a paper material having a two-dimensional cross section.

[0015] In an eleventh embodiment, the paper material of the tenth embodiment has a middle portion and end portions on either side of the middle portion. The middle portion is thinner than the end portions.

[0016] In a twelfth embodiment, a system includes a supply of sheet material, a housing configured to receive the sheet material from the supply, a conversion system located inside of the housing and configured to receive a sheet material, a cutting mechanism located inside of the housing and downstream of the conversion sy stem, and the discharge chute of any of the preceding embodiments. The discharge chute is located inside of the housing and downstream of the cutting mechanism. The conversion system is configured to convert the sheet material into the dunnage material. The cutting mechanism is configured to selectively cut the dunnage material. The discharge chute is arranged in the housing so that the dunnage material exits the housing through the outlet of the discharge chute.

[0017] In a thirteenth embodiment, the supply of the twelfth embodiment is a roll of the sheet material.

[0018] In a fourteenth embodiment, the supply of the twelfth embodiment is a fanfolded stack of the sheet material.

[0019] In a fifteenth embodiment, the sheet material of any of the twelfth to fourteenth embodiments is a paper material.BRIEF DESCRIPTION OF THE DRAWING

[0020] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0021] Fig. 1 A depicts an embodiment of a dunnage conversion system, in accordance with the embodiments described herein;

[0022] Fig. IB depicts another embodiment of a dunnage conversion system, in accordance with the embodiments described herein;Attorney Docket No. P46183-WO

[0023] Fig. 1C depicts a side schematic view of the dunnage conversion system, in accordance with the embodiments described herein;

[0024] Fig. 2 depicts one embodiment of a chart of a length between an opening of a cover and a danger based on a shape of the opening and a size of the opening of the cover, in accordance with the embodiments described herein;

[0025] Figs. 3A and 3B depict examples of slot and circular shapes, respectively, of outlets on the outlet sides of discharge chutes;

[0026] Fig. 4 depicts an example of a dunnage material converted from a sheet of kraft paper, in accordance with the embodiments described herein;

[0027] Figs. 5A, 5B, 5C, and 5D depict outlet end, top, inlet end, and side views, respectively, of an embodiment of a discharge chute, in accordance with the embodiments described herein;

[0028] Fig. 6 depicts an example of the dunnage material show n in Fig. 4 being discharged from the discharge chute shown in Figs. 5 A to 5D via the outlet of the discharge chute, in accordance with the embodiments described herein; and

[0029] Figs. 7A and 7B depict outlet and inlet end views, respectively, of another embodiment of a discharge chute, in accordance with the embodiments described herein.DETAILED DESCRIPTION

[0030] Depicted in Fig. 1A is an embodiment of a dunnage conversion system 2. The dunnage conversion system 2 includes a source 4 of sheet material 6. In the depicted embodiment, the source 4 is a roll of the sheet material 6. In some embodiments, the sheet material 6 is a paper-based material, such as Kraft paper. In the source 4, the sheet material 6 is in a substantially flat configuration. For example, the roll may hold a single ply of Kraft paper that is flat across the width of the roll. In another example, the roll may hold multi-ply sheet material where each ply is flat across the width of the roll. In another example, a single sheet of paper may be folded longitudinally so that the paper on either side of the fold is flat and the paper is rolled such that the longitudinal fold is on one side of the roll and the two longitudinal edges are on the other side of the of roll. Many other variations of the source 4 of the sheet material 6 in the form of a roll are possible.Attorney Docket No. P46183-WO

[0031] The dunnage conversion system 2 includes a dunnage conversion machine 8. The dunnage conversion machine 8 is configured to configured to convert the sheet material from the substantially flat configuration of the sheet material 6 into a non-flat configuration of a pad 10. In some embodiments, the sheet material 6 is Kraft paper and the dunnage conversion machine 8 is configured to manipulate the Kraft paper in such a way as to convert the paper into the pad 10 that can serve as a low-density void fill material. In some embodiments, the dunnage conversion machine 8 includes a severing mechanism to cut the pad 10 at intervals to form individual pads. In some embodiments, the dunnage conversion machine 8 further includes a drive system configured to feed (e.g., pull) the sheet material 6 from the source 4 into the dunnage conversion machine 8 and to feed the sheet material 6 through the dunnage conversion machine 8 as the sheet material 6 is converted into the pad 10.

[0032] Depicted in Fig. IB is another embodiment of a dunnage conversion system 12. The dunnage conversion system 12 includes a source 14 of sheet material 16. In the depicted embodiment, the source 14 is a fanfolded stack of the sheet material 16. In some embodiments, the sheet material 1 is a paper-based material, such as Kraft paper. In the source 14, the sheet material 16 is in a substantially flat configuration. For example, the fanfolded stack may hold a single ply of Kraft paper that is flat between the transverse folds and across the width of the fanfolded stack. In another example, the fanfolded stack may hold multi-ply sheet material where each ply is flat between the transverse folds and across the width of the fanfolded stack. Many other variations of the source 4 of the sheet material 6 in the form of a fanfolded stack are possible. The dunnage conversion machine 8 in the dunnage conversion system 12 is the same as the dunnage conversion machine 8 in the dunnage conversion system 2 and is capable of converting the sheet material 16 into the pad 18.

[0033] Depicted in Fig. 1C is a side schematic view of the dunnage conversion system 8. In the depicted embodiment, the system 8 includes a housing 40 having an inlet 42 and an outlet 44. At the moment shown in Fig. 1C, a sheet material 26 is being drawn into the housing 40 through the inlet 42 from a supply. In some embodiments, the supply of the sheet material 26 can be a roll of the sheet material 26, similar to the roll shown in the source 4 of Fig. 1A, or a fanfolded stack of the sheet material 26, similar to the fanfolded stack shown in the source 14 of Fig. IB. The sheet material 26 is pulled by a drive system 46 located inside of the housingAttorney Docket No. P46183-WO40 of the dunnage conversion machine 8. The drive system 46 is configured to convert the sheet material 26 into dunnage material 30 that has a non-flat configuration.

[0034] The dunnage conversion machine 8 includes a severing mechanism 48 configured to cut the dunnage material 30 at intervals to form individual pads of the dunnage material 30. The severing mechanism 48 can include a blade, a knife, a perforation tool, a notched blade, any plurality of the foregoing, or any combination thereof. In some cases, the severing mechanism 48 partially cuts through the dunnage material 30 to form a connected pad that can be tom away by a user, such as the severing mechanisms described in U.S. Patent No. 11.584.102 and U.S. Patent Application No. 18 / 722,006, the contents of each of which are hereby incorporated by reference in their entirety.

[0035] The dunnage conversion machine 8 further includes a discharge chute 50 that is located downstream of the severing mechanism 48. The dunnage material 30 passes through discharge chute 50 after the dunnage material 30 passes the severing mechanism 48. After passing through the discharge chute 50, the dunnage material 30 exits the outlet 44 of the housing 40. In some embodiments, an outlet of the discharge chute 50 is also the outlet 44 of the housing 8.

[0036] As discussed in greater detail below, the discharge chute 50 provides a measure of safety for a user by deterring the user from coming into contact with the severing mechanism 48. In some examples, the discharge chute 50 occupies a space between the severing mechanism 48 and the outlet 44 of the housing 40. In the depicted embodiment, a length 52 of the discharge chute 50 ensure that the distance between the severing mechanism 48 and the outlet 44 is greater than the length 52 of the discharge chute 50. In another example, the outlet of the discharge chute 50 can have a shape and / or size that minimizes the risk that a user’s fingers, hands, or arms can reach the severing mechanism 48, thus deterring injury to users.

[0037] Fig. 2 depicts a chart of a length s between an opening of a cover and a danger based on a shape of the opening and a size e of the opening of the cover. The chart shows the shapes of a slot, a square, and a circle of an opening. The size e of the opening refers to the width of the slot, the width of the square, and the diameter of the opening. The length s is the minimum recommended distance betw een the opening of the cover and the danger for user safety. In one example, when the opening is a slot with a width e that is greater than 4 mmAttorney Docket No. P46183-WO and less than or equal to 6 mm, the minimum distance 5 between the opening and the danger is 10 mm. However, when the opening is a square with a width e that is greater than 4 mm and less than or equal to 6 mm or a circle with a diameter e that is greater than 4 mm and less than or equal to 6 mm, the minimum distance . between the opening and the danger is only 5 mm. In another example, when the opening is a slot with a width e that is greater than 12 mm and less than or equal to 20 mm or a square with a width e that is greater than 12 mm and less than or equal to 20 mm or a circle with a diameter e that is greater than 12 mm and less than or equal to 20 mm, the minimum distance s between the opening and the danger is 120 mm.

[0038] In some cases, the minimum distance 5 between the opening and the danger can vary drastically based on the shape. For example, when the opening is a slot with a width e that is greater than 30 mm and less than or equal to 40 mm, the minimum distance \ betw een the opening and the danger is 850 mm. However, when the opening is a square with a width e that is greater than 30 mm and less than or equal to 40 mm, the minimum distance s between the opening and the danger is only 200 mm. And, when the opening is a circle with a diameter e that is greater than 30 mm and less than or equal to 40 mm, the minimum distance .s' between the opening and the danger is only 120 mm. The 850 mm distance .s' when the opening is a slot is significantly greater that the 120 mm distance .s' when the opening is a circle.

[0039] Figs. 3A and 3B depict examples of slot and circular shapes, respectively, of outlets on the outlet sides of discharge chutes. Fig. 3A depicts an embodiment of a discharge chute 60 that has an outlet end 62 with an outlet 64. The outlet 64 is in the shape of a slot. The slot has a width 66. In some embodiments, the width 66 of the outlet 64 is selected based on an expected size of the dunnage material that will pass through the discharge chute 60. For example, if the dunnage material is expected to be up to 30 mm thick, the width 66 of the outlet 64 can be 30 mm. Referring back to the chart in Fig. 2, when the outlet 64 is in the shape of a slot with the width of 30 mm, the discharge chute 60 w ould need to have a length of 850 mm. In some embodiments, the width 66 of the outlet 64 is selected based on a desired length of the discharge chute 60. For example, if the discharge chute is to be 120 mm, then the width 66 of the slot of the outlet 64 would need to be less than or equal to 20 mm.Attorney Docket No. P46183-WO

[0040] Fig. 3B depicts an embodiment of a discharge chute 70 that has an outlet end 72 with an outlet 74. The outlet 74 is in the shape of a circle. The circle has a diameter 76. In some embodiments, the diameter 76 of the outlet 74 is selected based on an expected size of the dunnage material that will pass through the discharge chute 70. For example, if the dunnage material is expected to be up to 80 mm wide, the diameter 76 of the outlet 74 can be 80 mm. Referring back to the chart in Fig. 2, when the outlet 74 is in the shape of a circle with the diameter of 80 mm, the discharge chute 70 would need to have a length of 850 mm. In some embodiments, the diameter 76 of the outlet 74 is selected based on a desired length of the discharge chute 70. For example, if the discharge chute is to be 120 mm, then the diameter 76 of the circle of the outlet 74 would need to be less than or equal to 30 mm.

[0041] Fig. 4 depicts an example of a dunnage material 80 that was converted from a sheet of kraft paper. The dunnage material 80 is non-planar with a three-dimensional shape. In particular, the cross section of the dunnage material 80 includes a middle section 82 and lateral end sections 84 on either side of the middle section 82. One effect of the conversion process is that the lateral end sections 84 tend to be thicker than the middle section 82. In the depicted embodiment, the lateral width of the dunnage material 80 is significantly greater than the thickness of each of the lateral end sections 84. It will be understood that the conversion process does not produce a uniform shape of the dunnage material 80 through its length. The thicknesses and sizes of the middle section 82 and the lateral end sections 84 of the dunnage material 80 at different locations along its length. As can be seen, the dunnage material 80 has a two-dimensional cross section with both a width and a thickness.

[0042] One challenge with the safety consideration is finding a combination of outlet shape, outlet size, and discharge chute length that will work for the dunnage material to pass through the discharge chute and for the discharge chute to fit in the housing of a dunnage machine. For example, the lateral width of the dunnage material 80 may be up to 80 mm and the thickness of the dunnage material 80 in the lateral end sections 84 may be up to 35 mm. At the same time, a dunnage machine may have space to accommodate a discharge chute that does not exceed 120 mm in length. Under these conditions, none of the shapes of an outlet for the discharge chutes listed in the chart in Fig. 2 will satisfy all of the constraints. If the outlet had a slot shape, the width of the slot would need to be at least 35 mm to accommodate the thickness of the lateral end sections 84; however, a slot with a width of 35 mm wouldAttorney Docket No. P46183-WO require the discharge chute to be 850 mm in length. If the outlet had a square shape, the width of the square would need to be at least 80 mm to accommodate the lateral width of the dunnage material 80: however, a square with a width of 80 mm would require the discharge chute to be 850 mm in length. If the outlet had a circle shape, the diameter of the circle w ould need to be at least 80 mm to accommodate the lateral width of the dunnage material 80; how ever, a circle with a diameter of 80 mm would require the discharge chute to be 850 mm in length.

[0043] Embodiments of discharge chutes below include outlets having a shape that includes a slot portion and circular portions on the ends of the slot portion. The width of the slot portion is less than a diameter of each of the circular portions. When used with dunnage material having a middle section and lateral end sections that are thicker than the middle section, the shape of the outlet accommodates the thinner middle section through the slot portion of the outlet and the thicker lateral end sections through the circular portions of the outlet. The width of the slot portion and the diameters of the circular portions can be selected such that the length of the discharge chute is less than it would be if the outlet was either a slot or a circle.

[0044] Figs. 5A, 5B, 5C, and 5D depict outlet end, top, inlet end, and side views, respectively, of an embodiment of a discharge chute 100. The discharge chute 100 has an inlet side 102 and an outlet side 104. The inlet side 102 of the discharge chute includes an inlet 110 and the outlet side 104 of the discharge chute 100 includes an outlet 120. The inlet and outlet 110 and 120 of the discharge chute 100 are separated by a length 106 of the discharge chute 100. The inlet 110 and outlet 120 are in fluid communication through the discharge chute 100 so that dunnage material received by the inlet 110 can pass through the discharge chute 100 from the inlet 110 to the outlet 120 and be discharged through the outlet 120. In some embodiments, the discharge chute 100 includes funneling surfaces 112 betw een the inlet 110 and the outlet 120. The funneling surfaces 112 are arranged to guide the dunnage material from the inlet 110 to the outlet 120 as the dunnage material passes through the discharge chute 100. In some embodiments, an area of the inlet 110 is greater than an area of the outlet 120 and the funneling surfaces 1 12 assist the dunnage material in transitioning from the area of the inlet 110 to the area of the outlet 120.Attorney Docket No. P46183-WO

[0045] In the depicted embodiment, the inlet 110 is generally rectangular in shape. In other embodiments, the inlet 110 can be any other shape. In the depicted embodiment, the outlet 120 includes a slot portion 122 and circular portions 124 on the ends of the slot portion 122. The slot portion 122 is generally linear and extends between the circular portions 124. The slot portion 122 has a width 126 and the circular portions 124 have diameters 128. The width 126 of the slot portion 122 is less than each of the diameters 128 of the circular portions 124. In the depicted embodiment, the diameters 128 of the circular portions 124 are the same. In other embodiments, the diameters 128 of the circular portions 124 can be different. Fig. 5 A shows a centerline 130 of the slot portion 122 and centers 132 of the circular portions 124. In the depicted embodiment, the centerline 130 of the slot portion 122 is aligned with the centers 132 of the circular portions 124. Fig. 5 A also shows a distance 134 between the centers 132 of the circular portions 124. In some embodiments, the distance 134 between the centers 132 of the circular portions 124 is at least 25% greater than the diameters 128 of the circular portions 124 (or the largest of the diameters 128 of the circular portions 124 if the diameters 128 are different).

[0046] The shape of the outlet 120 can allow the dunnage material 80 to be discharged after the dunnage material 80 passes through the discharge chute 100. Fig. 6 depicts an example of the dunnage material 80 being discharged from the discharge chute 1 0 via the outlet 120. In the depicted embodiment, the middle section 82 of the dunnage material 80 passes through the slot portion 122 of the outlet 120 and the lateral end sections 84 of the dunnage material 80 pass through the circular portions 124 of the outlet 120. Because the diameters 128 of the circular portions 124 are greater than the width 126 of the slot portion 122. the circular portions 124 are able to allow the thicker lateral end sections 84 of the dunnage material 80 to pass while the narrower middle section 82 of the dunnage material 80 can pass through the slot portion 122 of the outlet 120. This shape of the slot portion 122 and the circular portions 124 of the outlet 120 significantly reduce the likelihood that the dunnage material 80 will jam inside of the discharge chute 100.

[0047] The shape of the outlet 120 also allows the length 106 of the discharge chute 100 to be relatively short. In one example, the lateral width of the dunnage material 80 may be up to 90 mm, the thickness of the dunnage material 80 in the lateral end sections 84 may be up to 35 mm, and the thickness of the dunnage material 80 in the middle section 82 may be up toAttorney Docket No. P46183-WO15 mm. With those dimensions of the dunnage material 80, the width 126 of the slot portion 122 can be 20 mm. the diameters 128 of the circular portions 124 can be 40 mm, and the distance 134 between the centers 132 of the circular portions 124 can be 60 mm. These dimensions of the outlet 120 can accommodate the dunnage material 80 with some leeway for variations in the size of the dunnage material 80 along its length. In addition, referring back to Fig. 2, the width 126 of the slot portion 122 being 20 mm allows for a length 106 of the discharge chute 100 to be 120 mm and the diameters 128 of the circular portions 124 being 40 mm allow for length 106 of the discharge chute 100 to be 120 mm. Thus, with the shape and size of the outlet 120, the length 106 of the discharge chute 100 can be only 120 mm while still providing a safe distance for users.

[0048] Figs. 7A and 7B depict outlet and inlet end views, respectively, of another embodiment of a discharge chute 200. The discharge chute 200 has an inlet side 202 and an outlet side 204. The inlet side 202 of the discharge chute includes an inlet 210 and the outlet side 204 of the discharge chute 200 includes an outlet 220. The inlet and outlet 210 and 220 of the discharge chute 200 are separated by a length of the discharge chute 200. The inlet 210 and outlet 220 are in fluid communication through the discharge chute 200 so that dunnage material received by the inlet 210 can pass through the discharge chute 200 from the inlet 210 to the outlet 220 and be discharged through the outlet 220. In some embodiments, the discharge chute 200 includes funneling surfaces 212 betw een the inlet 210 and the outlet 220. The funneling surfaces 212 are arranged to guide the dunnage material from the inlet 210 to the outlet 220 as the dunnage material passes through the discharge chute 200. In some embodiments, an area of the inlet 210 is greater than an area of the outlet 220 and the funneling surfaces 212 assist the dunnage material in transitioning from the area of the inlet 210 to the area of the outlet 220.

[0049] In the depicted embodiment, the inlet 210 is generally rectangular in shape. In other embodiments, the inlet 210 can be any other shape. In the depicted embodiment, the outlet 220 includes a slot portion 222 and circular portions 224 on the ends of the slot portion 222. The slot portion 222 is generally linear and extends between the circular portions 224. The slot portion 222 has a width 226 and the circular portions 224 have diameters 228. The width 226 of the slot portion 222 is less than each of the diameters 228 of the circular portions 224. In the depicted embodiment, the diameters 228 of the circular portions 224 are the same. InAttorney Docket No. P46183-WO other embodiments, the diameters 228 of the circular portions 224 can be different. Fig. 7A shows a centerline 230 of the slot portion 222 and centers 232 of the circular portions 224. In the depicted embodiment, the centerline 230 of the slot portion 222 is offset from the centers 232 of the circular portions 224. This offset between the centerline 230 of the slot portion 222 and the centers 232 of the circular portions 224 can better accommodate cross-sectional shapes of some dunnage materials, as discussed below. Fig. 7A also shows a distance 234 between the centers 232 of the circular portions 224. In some embodiments, the distance 234 between the centers 232 of the circular portions 224 is at least 25% greater than the diameters 228 of the circular portions 224 (or the largest of the diameters 228 of the circular portions 224 if the diameters 228 are different).

[0050] The shape of the outlet 220 can allow the dunnage material 80 to be discharged after the dunnage material 80 passes through the discharge chute 200. For example, the dunnage material 80 can be discharged from the discharge chute 200 via the outlet 220. In that example, the middle section 82 of the dunnage material 80 can pass through the slot portion 222 of the outlet 220 while the lateral end sections 84 of the dunnage material 80 pass through the circular portions 224 of the outlet 220. Because the diameters 228 of the circular portions 224 are greater than the width 226 of the slot portion 222, the circular portions 224 are able to allow the thicker lateral end sections 84 of the dunnage material 80 to pass while the narrower middle section 82 of the dunnage material 80 can pass through the slot portion 222 of the outlet 220. This shape of the slot portion 222 and the circular portions 224 of the outlet 220 significantly reduce the likelihood that the dunnage material 80 will jam inside of the discharge chute 200. In addition, the lateral end sections 84 may extend upward from the top of the middle section 82 than the lateral end sections 84 extend downward from the bottom of the middle section 82. In this case, the offset of the centerline 230 of the slot portion 222 below the centers 232 of the circular portions 224 can allow the outlet 220 to better correspond with the cross-sectional shape of the dunnage material 80 and further reduce the likelihood that the dunnage material 80 will jam inside of the discharge chute 200.

[0051] The shape of the outlet 220 also allows the length of the discharge chute 200 to be relatively short. In one example, the lateral width of the dunnage material 80 may be up to 90 mm, the thickness of the dunnage material 80 in the lateral end sections 84 may be up to 35 mm, and the thickness of the dunnage material 80 in the middle section 82 may be up to 25Attorney Docket No. P46183-WO mm. With those dimensions of the dunnage material 80, the width 226 of the slot portion 222 can be 20 mm, the diameters 228 of the circular portions 224 can be 40 mm, and the distance 234 between the centers 232 of the circular portions 224 can be 60 mm. These dimensions of the outlet 220 can accommodate the dunnage material 80 with some leeway for variations in the size of the dunnage material 80 along its length. In addition, referring back to Fig. 2, the width 226 of the slot portion 222 being 20 mm allows for a length of the discharge chute 200 to be 220 mm and the diameters 228 of the circular portions 224 being 40 mm allow for length of the discharge chute 200 to be 220 mm. Thus, with the shape and size of the outlet 220, the length 206 of the discharge chute 200 can be only 220 mm while still providing a safe distance for users.

[0052] It will be understood that either of the discharge chutes 100 and 200 can be used in a dunnage conversion machine. For example, in the dunnage conversion system 8 shown in Fig. 1C, the either of the discharge chutes 100 and 200 can be used as the discharge chute 50. Using either of the discharge chutes 100 and 200 as the discharge chute 50 can minimize the length 52 of the discharge chute 50 so that the size of the housing 40 can be as small as possible. In some cases, users want the dunnage conversion system 8 to have the smallest footprint possible to minimize the amount of space required in a packaging facility for the dunnage conversion system 8. The minimization of the length 52 of the discharge chute 50 and therefore the size of the housing 40 can held reduce the footprint of the dunnage conversion system 8 as much as possible. And, the shapes of the outlets 120 and 220 in the discharge chutes 100 and 200 can provide the desired throughput of dunnage material 30 while also reducing the likelihood of jamming of the dunnage material 30 as is passes through the outlet chute.

[0053] For purposes of this disclosure, terminology such as “upper,” “lower.” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings,Attorney Docket No. P46183-WO and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value.

[0054] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.

Claims

Attorney Docket No. P46183-WOCLAIMSWhat is claimed is:1 . A discharge chute, comprising: an inlet side comprising an inlet configured to receive dunnage material; and an outlet side comprising an outlet configured to discharge the dunnage material; wherein the inlet and the outlet are in fluid communication through the discharge chute so that the dunnage material can pass through the discharge chute from the inlet to the outlet; wherein the outlet has a shape, comprising: a slot portion. a first circular portion on a first end of the slot portion, and a second circular portion on a second end of the slot portion; wherein a width of the slot portion is less than each of a diameter of the first circular portion and a diameter of the second circular portion.

2. The discharge chute of claim 1, wherein each of the diameter of the first circular portion and the diameter of the second circular portion is less than or equal to 40 mm.

3. The discharge chute of claim 2, wherein the width of the slot portion is less than or equal to 20 mm.

4. The discharge chute of claim 3, wherein a length of the discharge chute between the inlet side and the outlet side is greater than or equal to 120 mm.

5. The discharge chute of claim 1, wherein a centerline of the slot portion is aligned with a center of the first circular portion and a center of the second circular portion.

6. The discharge chute of claim 1 , wherein a centerline of the slot portion is offset from a center of the first circular portion and from a center of the second circular portion.Attorney Docket No. P46183-WO7. The discharge chute of claim 1, wherein a distance between a center of the first circular portion and a center of the second circular portion is at least 25% greater than the larger of a diameter of the first circular portion and a diameter of the second circular portion.

8. The discharge chute of claim 1, wherein an area of the inlet is greater than an area of the outlet.

9. The discharge chute of claim 1, further comprising: a funneling surface between the inlet and the outlet, wherein the funneling surface is arranged to guide the dunnage material from the inlet to the outlet as the dunnage material passes through the discharge chute.

10. The discharge chute of claim 1, wherein the dunnage material is a paper material having a two-dimensional cross section.

11. The discharge chute of claim 10. wherein the paper material has a middle portion and end portions on either side of the middle portion, and wherein the middle portion is thinner than the end portions.

12. A system comprising: a supply of sheet material; a housing configured to receive the sheet material from the supply; a conversion system located inside of the housing and configured to receive a sheet material; a cutting mechanism located inside of the housing and downstream of the conversion system; and the discharge chute of claim 1. wherein the discharge chute is located inside of the housing and downstream of the cutting mechanism; wherein the conversion system is configured to convert the sheet material into the dunnage material; wherein the cutting mechanism is configured to selectively cut the dunnage material; andAttorney Docket No. P46183-WO wherein the discharge chute is arranged in the housing so that the dunnage material exits the housing through the outlet of the discharge chute.

13. The system of claim 12, wherein the supply is a roll of the sheet material.

14. The system of claim 12, wherein the supply is a fanfolded stack of the sheet material.

15. The system of claim 12, wherein the sheet material is a paper material.

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