Flexible Dunnage Accumulator for Variable Volume Handling

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Solution Overview

Problem

Existing dunnage conversion machines struggle to efficiently produce and handle crumpled dunnage for effective cushioning and protection of products during transport and storage, as they often require manual cutting and lack efficient accumulation and dispensing systems.

Innovation Solution

A dunnage accumulator system with flexible holding portions and a sensor to detect full position, allowing for automatic adjustment of accumulation space and compression of dunnage, integrated with a dunnage machine that cross-crumples sheet stock for producing crumpled dunnage, facilitating efficient handling and storage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a continuous strip of dunnage is produced by running paper through a crumpling machine, then the dunnage can effectively cushion and protect products, but the exiting material requires manual cutting to free it from the machine and to provide desired length units

Engineering Contradiction:

Improvedunnage production efficiencyVSAvoidmanual cutting requirement

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The continuous dunnage strip is divided into discrete units of desired length using a severing assembly with blades that cut the material at predetermined intervals, eliminating manual cutting while maintaining product integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system automatically performs the cutting operation through integrated severing mechanisms that operate continuously alongside the crumpling process, freeing the material from the machine without human intervention

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If the dunnage accumulation space is fixed, then the structure is simple, but it cannot accommodate varying amounts of dunnage produced at different rates

Engineering Contradiction:

Improveaccumulation space flexibilityVSAvoidholding portion structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The holding portions are designed with flexible characteristics that allow them to expand and contract dynamically, accommodating varying volumes of accumulated dunnage while maintaining structural integrity and preventing material spillage

Inventive Principle:

Principle #15Dynamics

3Productivity

If the dunnage machine operates continuously to maximize production, then productivity increases, but the accumulation space may become full and require frequent intervention

Engineering Contradiction:

Improvecontinuous production rateVSAvoidintervention frequency

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The sensor detects the full position of the accumulation space in advance, triggering the dispensing mechanism to release dunnage units before the space is completely full, allowing continuous operation without abrupt interruptions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor provides real-time feedback on the accumulation space status, enabling automatic control of the dispensing mechanism to maintain optimal operating conditions and minimize intervention requirements

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS9694555B2Flexible dunnage handler

Publication Date: 2017.07.04 PREGIS LLC

AI summary

A dunnage accumulator includes a first holding portion (502) and a second holding portion (504) configured and associated with the first holding portion to define a dunnage accumulation space therebetween and for receiving and removably retaining dunnage from a dunnage machine (17) in the accumulation space, wherein at least a portion of the second holding portion is flexible such that flexing thereof varies the accumulation space to accommodate a varying amount of dunnage held therein.