Dunnage Distribution Assembly with Tiltable Support Surface
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Solution Overview
Problem
Existing packaging systems face inefficiencies in distributing and aligning dunnage products, such as cushioning pads, to multiple packing stations, leading to random movement and misalignment issues during delivery.
Innovation Solution
A packaging system with a distribution assembly that includes an alignment device with an inclined surface and a tiltable support surface, which guides and directs dunnage products from a converter to specific packing stations, ensuring consistent orientation and efficient delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional discharge system is used to deliver dunnage products, then the discharge direction is predetermined and simple, but the dunnage products experience random movement and misalignment when delivered to multiple packing stations
Solution Approach 1:
The support surface is made tiltable to dynamically adjust the direction in which dunnage products are delivered. By changing the tilt angle of the support surface, the system can direct dunnage products to different packing stations while maintaining alignment precision, resolving the contradiction between precision and complexity.
Solution Approach 2:
The alignment device with inclined surface acts as an intermediary between the dunnage product discharge and the packing stations. It receives dunnage products in a first direction and guides them to fall onto the support surface in a controlled second direction, preventing random movement and misalignment.
2Adaptability or versatility
If multiple packing stations are served simultaneously, then the packaging system becomes more versatile, but the distribution of dunnage products becomes more complex and less efficient
Solution Approach 1:
The tiltable support surface enables the system to adapt to different packing station locations by dynamically adjusting the tilt angle. This allows a single distribution assembly to efficiently serve multiple packing stations without reducing distribution efficiency, as the system can be quickly reconfigured to direct dunnage products to the required station.
Solution Approach 2:
The distribution assembly is designed to perform multiple functions by serving different packing stations through the tiltable support surface. The same alignment device and support surface structure can direct dunnage products to various stations, providing versatility while maintaining operational efficiency through a unified mechanism.
3Manufacturing precision
If dunnage products are discharged directly without guidance, then the discharge process is simple, but skewing and tilting occur during delivery to packing stations
Solution Approach 1:
The alignment device serves as an intermediary that receives dunnage products in a first direction and guides them to fall onto the support surface in a controlled second direction. This intermediate guidance mechanism prevents skewing and tilting, ensuring consistent product orientation while adding minimal operational complexity through a straightforward inclined surface 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 system effectively aligns and directs dunnage products to packing stations, preventing skewing and tilting, and automates the distribution process, enhancing packaging efficiency and consistency.
Implementation Method 1
an alignment device having an inclined surface inclined in a second direction transverse the first direction to guide dunnage products moving through the alignment device to fall onto the dunnage support surface
Implementation Method 2
The dunnage support surface is tiltable to selectively direct a dunnage product toward a respective packing station
Data Source
AI summary
A packaging system (10) and method for supplying and distributing dunnage products to multiple packing stations (14, 16) is characterized by a supply of dunnage products (12), a plurality of packing stations (14, 16), and a distribution assembly (20) that selectively distributes the dunnage products from the supply (12) to selected ones of the packing stations (14, 16). The supply of dunnage (12) may include a converter (22) that converts sheet stock material into a relatively less dense dunnage product. The distribution assembly (20) includes a conveyor (40), an alignment device (50) downstream of the conveyor (40), and a tiltable dunnage product support surface (60) below the alignment device (50). The alignment device (50) controls the descent of a dunnage product therethrough to the support surface (60). The support surface (60) is tiltable to selectively direct the dunnage product toward respective packing stations (14, 16).