Compact Dunnage Conversion System via Fan-Fold Orientation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dunnage conversion machines are wide and occupy significant space, and they require forming the sheet material before conversion, which is inefficient and space-consuming.
Innovation Solution
A method and apparatus that draw fan-folded sheet stock material from a stack in a direction parallel to the width dimension, reducing the need for forming devices and allowing for a more compact conversion machine, using rotating members to crumple and convert the material into a less dense dunnage product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dunnage conversion machines are used to convert sheet stock material, then dunnage product can be produced, but the machines occupy significant space and have a wide footprint
Solution Approach 1:
The patent changes the orientation of fold lines in the stack from extending perpendicular to the feed direction (conventional) to extending parallel to the feed direction. This dimensional reorientation allows the material to be fed through a narrower path, reducing the machine's width and overall footprint while maintaining production capability.
2Ease of manufacture
If sheet material is formed before conversion in conventional machines, then proper material configuration is achieved, but additional forming devices are required increasing complexity
Solution Approach 1:
The patent pre-folds the sheet material into a fan-folded stack configuration before it enters the conversion machine. This preliminary folding action eliminates the need for complex forming devices within the machine, as the material is already configured in the desired folded state ready for conversion.
Solution Approach 2:
The fan-folded stack configuration allows the material to feed itself through the machine without requiring additional forming mechanisms. The pre-established fold lines guide the material through the conversion process automatically, reducing device 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 solution results in a smaller, more compact dunnage conversion system that produces a less dense dunnage product with a narrower footprint, enabling higher density dunnage production and efficient use of space.
Implementation Method 1
the sheets deform from their planar state and crumple as they are drawn from the stack
Data Source
AI summary
A method of converting a supply of sheet stock into a relatively less dense dunnage product, including the following steps of (i) providing a stack of fan-folded sheet material having fold lines parallel to a width dimension; and (ii) drawing sheet stock material from the stack in a direction parallel to the width dimension.