Manual Dunnage Conversion Apparatus with Resilient Guide
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Solution Overview
Problem
Existing dunnage conversion machines are not ideal for all applications due to their size, complexity, and cost, and they do not efficiently produce a dunnage product with both cushioning and void-fill characteristics while occupying a reduced volume for transport and operation.
Innovation Solution
A manually-operated dunnage conversion apparatus made of paperboard, featuring a housing with a support and guide member to prevent tearing, and a tensioning assembly to apply compressive force, which expands pre-slit sheet material into a larger volume with reduced density, allowing for easy and cost-effective production of a dunnage product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing dunnage conversion machines are used, then dunnage product can be produced, but the machines are large, complex, and expensive
Solution Approach 1:
The apparatus is divided into distinct functional modules: a housing structure, a support member for the sheet material supply, a guide member with resilient surface, and a tensioning assembly. Each module performs a specific function and can be manufactured independently, simplifying the overall manufacturing process and reducing cost while maintaining functionality
Solution Approach 2:
The apparatus is designed to be simple and inexpensive to fabricate, potentially as a disposable or single-use device for specific packaging operations. The housing and components can be made from inexpensive materials like paperboard, eliminating the need for expensive, complex machinery while achieving the desired dunnage conversion function
2Volume of moving object
If existing dunnage conversion machines are used, then dunnage product can be produced, but they occupy large volume for transport and operation
Solution Approach 1:
The apparatus components are designed to be compact and potentially nested within each other when not in use. The support member and guide member can be positioned within the housing in a space-efficient manner, and the tensioning assembly can be collapsed or retracted, allowing the entire apparatus to occupy minimal space during transport and storage while maintaining full productivity during operation
Solution Approach 2:
The apparatus transforms sheet material from a compact two-dimensional state into an expanded three-dimensional dunnage product with increased volume and reduced density. This dimensional transformation occurs within the compact apparatus through the application of tension and guidance through the resilient surface, enabling large-volume dunnage production from a small-footprint device
3Reliability
If sheet material is drawn through the apparatus, then expansion occurs, but tearing may occur without proper guidance
Solution Approach 1:
The guide member with its resilient surface acts as an intermediary between the sheet material supply and the expansion zone. This resilient surface provides gentle guidance and support to the sheet material as it is drawn through the apparatus, distributing forces evenly and preventing localized stress concentrations that could cause tearing, while still allowing the material to expand freely
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 apparatus enables the production of an expanded dunnage product with enhanced cushioning and void-fill capabilities, occupying less volume and being simpler and more cost-effective than existing machines, while being recyclable and composed of renewable resources.
Implementation Method 1
a guide member downstream of the support and providing a resilient surface across which the sheet material may be drawn to restrict tearing of the sheet material
Implementation Method 2
a tensioning assembly coupled to the housing and to the support for applying a compressive force between opposite axial sides of the housing
Implementation Method 3
an expandable sheet material having a plurality of slits configured to expand under tension applied in a feed direction that is transverse a length dimension of the slits
Data Source
AI summary
A manually-operated dunnage conversion apparatus includes a housing, a support mounted in the housing and configured to support a supply of sheet material for dispensing from the dunnage conversion apparatus, and one or both of (a) a guide member mounted in the housing downstream of the support and providing a resilient surface across which the sheet material may be drawn to restrict tearing of the sheet material as it is drawn from the dunnage conversion apparatus, and (b) a tensioning assembly mounted in the housing and configured to apply a compressive force between opposite axial sides of the housing to control the force necessary to dispense the supply of sheet material. Except for the tensioning assembly, the apparatus may be made of paper-based products, making the apparatus recyclable, reusable, and composed of a renewable resource, as well as inexpensive to manufacture.