Automated Dunnage Dispenser with Self-Filling Curl Mechanism
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Solution Overview
Problem
The process of shipping goods often requires manual placement of dunnage material to prevent shifting and cushioning, which is labor-intensive and time-consuming, especially with high-speed dunnage conversion machines.
Innovation Solution
An automated system that feeds a continuous strip of dunnage into a container, using a dispenser to curl or fold the dunnage within the container and a container closer to partially or fully enclose it, eliminating the need for manual packing and ensuring efficient void filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a packer manually guides and pushes crumpled dunnage strip into container, then dunnage can be placed in container, but the process becomes difficult and tedious at high speeds
Solution Approach 1:
The dunnage strip is designed to automatically curl and fold back and forth within the container confines as it is fed from the dispenser outlet, eliminating the need for manual guidance and pushing by the packer. The strip self-positions and self-fills the container voids
Solution Approach 2:
The manual mechanical action of guiding and pushing crumpled dunnage is replaced by an automated dispenser system that feeds the strip at high speed while a container closer automatically moves to close the container
2Productivity
If continuous strip of dunnage is fed into container at high speed, then productivity increases, but manual guidance becomes tedious
Solution Approach 1:
The dunnage strip automatically performs the filling function without requiring continuous manual intervention. The strip curls and folds back and forth on its own within the container confines, freeing the packer from the tedious task of manual guidance
Solution Approach 2:
The manual guidance function is extracted from the packing process and replaced by the automated dispenser system. The packer's role is reduced to monitoring and container closing, while the dunnage strip handles the filling function autonomously
3Extent of automation
If automated dispenser feeds dunnage strip into container, then labor requirements decrease, but system complexity increases
Solution Approach 1:
The dispenser system is designed with an outlet that serves multiple functions: it feeds the dunnage strip, positions it for automatic curling, and works in conjunction with the container closer to complete the filling and closing operation. This multi-functionality reduces the need for separate complex mechanisms
Data Source
AI summary
A system (10) for automatically dispensing a strip of dunnage to a container (14) includes a dispenser (12) having an outlet (92) from which the dispenser can feed a length of a strip of dunnage lengthwise, a container support (36) for supporting a container (14) thereon, and a pusher device (114) at the outlet (92) for pushing, more particularly propelling, a trailing end of the strip of dunnage from the outlet (92) toward the container support (36). The outlet (92) is aligned with the container support (36). Thus the outlet (92) is positioned relative to a container (14) such that the strip will curl or fold back and forth upon itself within the confines of the container (14) as it is being fed from the outlet (92). A container closer (120, 130 and 32) automatically closes the flaps (80 and 82) of the container (14).