Fan-Folded Sheet Holder for Simultaneous Dunnage Feeding
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Solution Overview
Problem
Existing dunnage conversion machines face difficulties in simultaneously loading multiple plies of fan-folded sheet stock material, often resulting in waste and inefficient conversion due to uneven feeding from separate stacks.
Innovation Solution
A method and holder system that splits a single stack of single-ply fan-folded sheet stock material into two sub-stacks connected by a center fold line, allowing simultaneous feeding into a dunnage conversion machine, utilizing inclined support surfaces to maintain and separate the sub-stacks for efficient loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple separate stacks of sheet stock material are used to provide multi-ply material, then the dunnage conversion machine can achieve higher productivity, but the feeding process becomes complex and results in waste due to uneven feeding
Solution Approach 1:
The patent divides a single large stack of fan-folded sheet stock into multiple sub-stacks (e.g., four sub-stacks) that are fed simultaneously into the dunnage conversion machine. Each sub-stack is managed independently through guide members and support surfaces, simplifying the feeding mechanism while achieving multi-ply conversion. This segmentation approach maintains productivity without requiring complex multi-stack handling systems.
2Reliability
If separate stacks are used for each ply, then sufficient material supply is ensured, but waste occurs due to uneven feeding and difficulty in simultaneous loading
Solution Approach 1:
The patent combines multiple sub-stacks of sheet stock material into a unified feeding system where all sub-stacks are drawn simultaneously through the conversion machine. The guide members and support surfaces work together to synchronize the feeding of all sub-stacks, ensuring that material is consumed evenly from each stack. This merging approach eliminates the waste associated with uneven feeding while maintaining reliable material supply for multi-ply dunnage production.
3Device complexity
If a single stack is used, then device complexity is reduced, but the ability to provide multi-ply sheet stock material is limited
Solution Approach 1:
The patent utilizes the vertical dimension by stacking multiple layers of sheet stock material in a single large stack, with each layer forming a sub-stack. The fan-folded structure allows these layers to be separated and fed simultaneously through the conversion machine. This dimensional approach enables multi-ply output while maintaining a simple single-stack input configuration, avoiding the need for multiple separate stacks or complex loading mechanisms.
Data Source
AI summary
A supply of single-ply, fan-folded sheet stock material includes a holder that facilitates simultaneously loading multiple plies of sheet stock material into a dunnage conversion machine for conversion into a dunnage product. The holder has inclined support surfaces and intersecting support walls that support the support surfaces in their inclined orientations. The holder has a W-shape cross-section, with inclined outer support surfaces and inclined inner support surfaces that may meet in the middle. The inner support surfaces generally are perpendicular to adjacent outer support surfaces to support a generally rectangular stack and sub-stacks of single-ply, fan-folded sheet stock material. The inclined support surfaces of the holder facilitate splitting the stack in half and supporting the two sub-stacks so that pages on top of the two stacks, connected by a center fold line, can be drawn into the conversion machine simultaneously.