Top-Filling Dunnage Conversion Machine Void Filling
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Solution Overview
Problem
Existing dunnage conversion machines are inadequate for efficiently filling shallow voids in the upper portion of containers, as they often result in dunnage strips that do not separate and interact effectively to fully occupy the space, leading to incomplete filling and potential shifting of items during shipping.
Innovation Solution
A dunnage conversion machine and method that involves guiding multiple sheets of stock material to laterally-disposed regions of an inlet to prevent nesting, and converting them into strips that can separate and follow distinct paths, allowing the dunnage to randomly bend and fold to better fill the container void.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sheets of stock material are fed through a single inlet to a conversion assembly, then the dunnage strips can separate and follow different paths to better fill voids, but the sheets may wrap around each other and fail to separate properly
Solution Approach 1:
The single inlet is segmented into multiple separate inlets, with each inlet receiving a separate sheet of stock material. This segmentation prevents the sheets from wrapping around each other while allowing multiple strips to be produced simultaneously. The conversion assembly is divided into multiple conversion zones, each processing one sheet independently, ensuring reliable separation and path-following capability for better void filling.
2Device complexity
If sheets are guided to the same region of the inlet, then the conversion process is simplified, but the sheets wrap around each other and cannot follow separate paths
Solution Approach 1:
The guiding system directs sheets to different lateral regions of the inlet, utilizing the lateral dimension to prevent wrapping. Each sheet is guided to a distinct lateral position at the inlet, allowing the conversion assembly to process multiple sheets simultaneously without interference. This dimensional separation enables both simplified guiding and effective path separation for improved void filling.
Data Source
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AI summary
A dunnage conversion machine (10) and method for providing strips of dunnage that fill a void in a container are characterized by means (24) for separately guiding at least two sheets of stock material (14 and 16) to respective laterally-disposed regions of an inlet (20) to a conversion assembly (40) such that one sheet does not wrap around another sheet, and means (12) for converting the sheets into strips of dunnage that can readily separate and follow separate paths.