Cross-Crumpled Dunnage via Differential Speed Shearing
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Solution Overview
Problem
Existing dunnage systems struggle to efficiently convert sheet materials into effective cushioning products that can accommodate irregularly shaped products, often resulting in inadequate protection during transport and storage due to limitations in crumpling mechanisms and material utilization.
Innovation Solution
A crumpling apparatus with entry-side and exit-side crumpling members that operate at different speeds and are laterally displaced to create a crumpling zone, allowing for cross-crumping of sheet material to produce dunnage with enhanced pleating and crimped regions, effectively locking folds in place for improved protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crumpling mechanisms are used to convert sheet material into dunnage, then the basic cushioning function is achieved, but the protection effectiveness is insufficient for irregularly shaped products
Solution Approach 1:
The crumpling mechanism is divided into multiple crumpling members (first and second entry-side crumpling members, first and second exit-side crumpling members) that operate independently at different speeds. This segmentation allows each member to contribute differently to the crumpling process, creating enhanced pleating and crimped regions that improve protection effectiveness while maintaining manufacturing feasibility through modular design
Solution Approach 2:
The crumpling members are configured to move at different speeds, with entry-side members moving faster than exit-side members. This dynamic speed variation creates a crumpling zone where sheet material is progressively deformed, producing locked folds and enhanced pleating that significantly improve cushioning reliability for irregularly shaped products
2Reliability
If sheet material is crumpled longitudinally to form dunnage strips, then the dunnage can be produced efficiently, but the folds are not securely locked and protection is inadequate
Solution Approach 1:
The crumpling members create periodic crimped regions and pleats along the length of the dunnage strip through their coordinated motion. These periodic structures act as locking mechanisms that secure the folds in place, preventing unraveling while maintaining continuous production flow and efficiency
Solution Approach 2:
The crumpling process creates a composite structure within the single sheet material, combining smooth regions with highly crumpled pleated regions and crimped locked folds. This composite morphology provides both fold stability and efficient material utilization, ensuring adequate protection without sacrificing production speed
3Manufacturing precision
If the crumpling zone is created with laterally displaced crumpling members, then cross-crumping with enhanced pleating is achieved, but the device complexity increases
Solution Approach 1:
The crumpling members are laterally displaced relative to each other, creating a cross-crumping action that introduces complexity in the lateral dimension. This multi-dimensional crumpling produces enhanced pleating quality and locked folds, while the lateral arrangement of members allows for space-efficient design that manages structural complexity
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 system effectively converts sheet material into cross-crumpled dunnage with increased crimping and pleating, providing superior cushioning and protection for irregularly shaped products by ensuring the crumpled material is securely locked in place, enhancing protection during transport and storage.
Implementation Method 1
The first entry-side crumpling member can be configured for moving at a first rate and can be associated with the second entry-side crumpling member for moving sheet material through the entry in a first direction along a longitudinal path at an entry rate. Additionally, the first exit-side crumpling member can be configured for moving at a second rate and can be associated with the second exit-side crumpling member for moving the sheet material through the exit in the first direction along the path at an exit rate that is slower than the entry rate
Implementation Method 2
The entry and exit-side crumpling members can also be displaced laterally along the path with respect to each other to cause shearing of the sheet within the crumpling zone
Implementation Method 3
effectively locking folds in place for improved protection
Data Source
AI summary
A dunnage crumpling apparatus is provided having first and second entry-side crumpling members and first and second exit-side crumpling members. The first and second entry-side crumpling members define an entry therebetween. The first and second exit-side crumpling members define an exit therebetween that is disposed along the longitudinal path downstream of the entry. A crumpling zone being defined between the entry and exit. The first entry-side crumpling member is configured for moving at an first rate and is associated with the second entry-side crumpling member for moving sheet material through the entry in a first direction along a longitudinal path at an entry rate. The first exit-side crumpling member is configured for moving at an second rate and is associated with the second exit-side crumpling member for moving the sheet material through the exit in the first direction along the path at a exit rate that is slower than the entry rate to crumple the sheet material for producing dunnage. The entry and exit-side crumpling members are displaced laterally along the path with respect to each other to cause shearing of the sheet within the crumpling zone.