Helically-Crumpled Dunnage Conversion Machine
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Solution Overview
Problem
Existing dunnage materials, such as plastic foam peanuts and crumpled newspaper, are messy, occupy the same volume when stored and used, and require manual preparation, while existing dunnage conversion machines produce dunnage products in advance and then dispense them in bulk, lacking flexibility in production and storage efficiency.
Innovation Solution
A machine and method that converts sheet stock material into a helically crumpled dunnage product, utilizing a cylindrical mandrel and guide member to form a helical pre-form, which is then restricted to twist and crumple, providing lateral strength and increased cushioning, allowing for continuous production and on-demand or bulk dispensing of lower-density dunnage products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If dunnage material is produced in advance and dispensed in bulk (like foam peanuts), then storage efficiency is improved, but the material occupies the same volume when stored as when used, losing storage space efficiency
Solution Approach 1:
The patent applies parameter changes by transforming the density state of dunnage material. Stock material is stored in a high-density configuration (roll or fan-folded stack) and then converted to a lower-density expanded dunnage product on-site. This allows the material to occupy minimal storage space while providing maximum volume when deployed for cushioning and protection.
2Strength
If plastic foam peanuts are used for dunnage, then cushioning ability is improved, but the material is messy and occupies the same volume when stored as when used
Solution Approach 1:
The invention transforms compact stock material into expanded dunnage product through controlled deformation. The helical crumpling process creates a structured expansion that provides cushioning while containing the material in a defined form, preventing messiness associated with loose foam peanuts.
Solution Approach 2:
The patent uses a cylindrical mandrel with helical path configuration to create curved, helical crumpling patterns in the dunnage product. This curved deformation structure provides effective cushioning while maintaining a contained, non-messy form factor.
3Volume of moving object
If crumpled newspaper is used for dunnage, then storage efficiency is improved compared to foam, but manual crumpling is required which increases labor
Solution Approach 1:
The machine performs automatic crumpling and formation of dunnage product from stock material without requiring manual intervention. The system self-services by automatically feeding stock material through the helical crumpling mechanism and producing ready-to-use dunnage product, eliminating the need for manual crumpling while maintaining storage efficiency.
Solution Approach 2:
The patent replaces manual mechanical crumpling action with an automated mechanical system featuring a cylindrical mandrel, guide members, and controlled restriction mechanisms that automatically form helically crumpled dunnage product from stock material.
4Productivity
If existing dunnage conversion machines produce dunnage in advance and dispense in bulk, then production efficiency is improved, but flexibility in production is reduced
Solution Approach 1:
The patent implements a dynamic production system where stock material is converted to dunnage product on-demand rather than in advance bulk production. The machine can operate continuously to produce dunnage as needed, providing both efficiency through automation and flexibility through on-demand production capability.
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 helically crumpled dunnage product offers improved lateral strength and cushioning, enabling efficient production and storage as a high-density roll or fan-folded stack, which can be converted into a lower-density product on-site, reducing waste and manual labor.
Implementation Method 1
the restriction causing the pre-form to retard longitudinal advancement, to twist upon itself, and to permanently deform as it moves past the restriction, thereby longitudinally and helically crumpling the pre-form
Data Source
AI summary
A machine for converting a sheet stock material into a relatively less dense dunnage product includes both (a) a helical pre-form assembly having a cylindrical mandrel with a longitudinal axis and a guide member for guiding the sheet stock material from a supply thereof into a helical path along and around the mandrel so as to form a helical pre-form that rotates around the longitudinal axis and advances parallel to the longitudinal axis; and (b) a restriction in the path of the pre-form that slows the advance and rotation of the pre-form past the restriction, the restriction causing the pre-form to retard longitudinal advancement, to twist upon itself, and to permanently deform as it moves past the restriction, thereby longitudinally and helically crumpling the pre-form.