Dunnage Conversion Splicing with Mechanical Stapling
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Solution Overview
Problem
Existing splicing methods for dunnage conversion machines are inefficient, requiring adhesive tape or spray adhesive, which can cause delays and quality issues, and pre-applied adhesives incur disposal costs and operational challenges.
Innovation Solution
A dunnage conversion system that uses a stapler to mechanically fasten the leading and trailing portions of stock material with staples, creating a secure connection for seamless splicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is used to splice stock material, then the stock material can be joined, but the operator must have tape supply handy and the process becomes tedious with multi-ply rolls
Solution Approach 1:
The patent replaces the adhesive-based mechanical system with a mechanical fastening system using staples. The stapler mechanism drives staples through the stock material layers, creating mechanical interlocking bonds that are more reliable and easier to apply than adhesive tape, especially with multi-ply rolls where adhesive penetration is difficult.
Solution Approach 2:
The stapler mechanism is self-contained and does not require external adhesive supplies or complex application procedures. The operator simply positions the stock material and activates the stapler, which automatically delivers and secures the staples, making the splicing process simpler and more consistent.
2Reliability
If spray adhesive is used to splice stock material, then the leading and trailing ends can be bonded, but adhesive may be oversprayed causing jams or affecting machine operation
Solution Approach 1:
The patent eliminates the spray adhesive system entirely and replaces it with a mechanical stapling system. This substitution removes the harmful overspray effect completely, as staples are contained within the stapler mechanism and only deployed where needed, without affecting other machine components.
Solution Approach 2:
The patent extracts and removes the adhesive application system from the splicing process, eliminating the source of overspray problems. By using staples instead, the harmful adhesive material is completely removed from the system, preventing contamination and machine interference.
3Ease of operation
If pre-applied pressure-sensitive adhesive is used, then splicing can be facilitated, but release liners must be disposed of incurring costs and additional effort
Solution Approach 1:
The patent replaces the adhesive-based system with a mechanical stapling system, eliminating the need for release liners entirely. Staples are applied directly to the stock material without requiring any liner removal or disposal, reducing waste and operational steps.
Solution Approach 2:
The patent eliminates the disposable release liner component from the splicing process. By using reusable staples that remain embedded in the stock material, the system avoids the cycle of consuming and disposing of release liners, reducing waste and ongoing costs.
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
This method eliminates the need for adhesives, reduces operational delays, and ensures a strong, reliable bond without the disposal costs associated with pre-applied adhesives, enhancing productivity and dunnage product quality.
Implementation Method 1
a stapler to provide staples that mechanically interlock the leading and trailing portions and apply the staples to the leading and trailing portions to effect a connection therebetween
Data Source
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AI summary
A method that includes the steps of (i) attaching a leading portion of a supply of stock material to a trailing portion of a preceding supply of stock material by means of a mechanical fastener, an electromagnetic field, electrostatic charges, or an activatable bonding agent, and (ii) converting the stock material into a relatively less dense dunnage product. The attaching step may include (a) embossing, punching, stitching, stapling, riveting, clipping, snapping, buttoning, attaching with male and female interlocking devices or hook-and-loop fasteners, (b) integrating one or more elements into the stock material to provide a stock material with magnetic or magnetizable material in the leading or trailing portion, (c) imparting opposing and attractive magnetic charges in respective leading and trailing portions, (d) inducing an electrostatic charge or a magnetic field in at least one of the leading and trailing portions, and/or (e) activating a bonding agent.