Conical Dunnage Former for Compact High-Strength Paper Cushioning
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Solution Overview
Problem
Existing dunnage production equipment requires a large footprint and is inefficient in producing robust, space-efficient dunnage suitable for protecting heavier items.
Innovation Solution
A device comprising a former with a specific passage configuration and a crumpler that compresses overlapping layers of stock material into a low-density dunnage with a central spine and thicker lobes, using a spreader to maintain tube dimensions and a crumpler with compression elements to form the dunnage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional folding and compression equipment is used to produce robust dunnage with overlapping layers, then the dunnage structure and protection capability are improved, but the equipment footprint increases
Solution Approach 1:
The patent employs a nested former structure where an inner former is positioned within an outer former, both contributing to the bending and shaping of the stock material. This nested configuration allows the equipment to achieve robust dunnage formation in a more compact arrangement, reducing the overall equipment footprint while maintaining the necessary structural complexity for producing strong, multi-layered dunnage.
2Quantity of substance
If the passage aspect ratio is reduced to improve dunnage density and compactness, then the dunnage space efficiency is improved, but the manufacturing complexity of the passage increases
Solution Approach 1:
The passage is divided into multiple sections with different aspect ratios along the longitudinal axis. The first portion has a larger aspect ratio for initial material engagement, while the second portion has a smaller aspect ratio for final compacting. This segmentation allows the system to achieve high dunnage density in the final product while keeping individual passage sections manufacturable and simpler in design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device efficiently produces dunnage with a compact design, suitable for protecting heavier items by providing a central spine and thicker lobes, reducing equipment footprint and enhancing protection efficiency.
Implementation Method 1
a crumpler positioned downstream of the former with respect to the material path and configured to compress the overlapping layers of the stock material
Implementation Method 2
The interior surface is configured to bend the stock material into overlapping layers as the stock material moves through the passage
Data Source
AI summary
Devices for producing dunnage include a crumpler configured to convert a high-density stock material into low-density dunnage, and a former positioned upstream of the crumpler. The outer former has interior surface defining a passage configured to receive the inner former. The interior surface configured to fold the stock material into overlapping layers as the stock material moves through the passage. An outer surface of the inner former opposes and is spaced from the interior surface of the outer former so that the outer surface and the interior surface of the outer former define a channel for receiving the stock material.