Dunnage Roller Speed Differential Crumpling
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Solution Overview
Problem
Existing dunnage conversion machines are inefficient in producing crumpled paper dunnage that effectively fills void spaces in containers of varying shapes, leading to inadequate protection and potential damage during transport and storage.
Innovation Solution
A dunnage device with a mechanism that includes high-speed rollers and crumpling members to cross-crumple paper stock into dunnage units, utilizing a crumpling zone where entry-side rollers move faster than exit-side rollers to create a crumpled configuration with pleats and crimped regions, ensuring effective cushioning and space filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dunnage conversion machines are used to produce crumpled paper dunnage, then the dunnage can fill void spaces in containers, but the production efficiency is insufficient and the crumpling effect is inadequate for effective protection
Solution Approach 1:
The patent employs dynamic speed differential between entry-side rollers and exit-side rollers to create effective crumpling. The entry-side rollers operate at a first speed while exit-side rollers operate at a second speed, creating a speed differential that dynamically crumples the paper stock as it passes through the crumpling zone, thereby improving both production efficiency and protection effectiveness.
2Speed
If high-speed rollers are used to increase crumpling speed, then productivity improves, but the crumpling precision and fold locking may be insufficient
Solution Approach 1:
The patent uses dynamic speed differential between rollers to achieve both high crumpling speed and precise fold locking. The controlled speed difference between entry-side and exit-side rollers creates consistent crumpling patterns with proper fold locking, maintaining manufacturing precision while improving crumpling speed.
Solution Approach 2:
The patent changes the speed parameter of the rollers to optimize crumpling performance. By adjusting the speed differential between entry-side and exit-side rollers, the system achieves both high productivity and precise fold locking, resolving the contradiction between speed and precision.
3Reliability
If the crumpling zone is designed with speed differential between rollers, then effective crumpling is achieved, but the device complexity increases
Solution Approach 1:
The patent implements a dynamic speed differential system between entry-side and exit-side rollers to achieve effective crumpling. This dynamic approach creates the necessary speed variation for proper crumpling while using a relatively simple mechanical roller system, balancing crumpling effectiveness with acceptable 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 device produces dunnage that effectively cushions products and fills container voids, providing enhanced protection against damage during transport and storage by creating a crumpled configuration with increased crimping and locking of folds, ensuring reliable and efficient packing operations.
Implementation Method 1
a crumpling zone where entry-side rollers move faster than exit-side rollers to create a crumpled configuration
Implementation Method 2
A dunnage device with a mechanism that includes high-speed rollers and crumpling members to cross-crumple paper stock into dunnage units
Data Source
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AI summary
A dunnage device (10) including a dunnage mechanism (14) comprising first and second dunnage converting portions (24,26) that have an engaged condition, in which the converting portions are associated and configured for converting stock material into dunnage and a disengaged condition in which the converting portions are disabled from converting the stock into dunnage and a dunnage handler (18) configured for receiving the dunnage from the dunnage mechanism and including a first handler portion (504) that has a handling position in which the dunnage handler is configured for controlling the dunnage and a release position, wherein the first handler portion is associated with the dunnage mechanism such that movement of the first handler portion from the handling position to the release position causes the dunnage mechanism to change from the engaged condition to the disengaged position.