Palletized Fan-Folded Stock Layout for Continuous Dunnage Feed
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Solution Overview
Problem
The need to connect multiple fan-folded paper stacks on a pallet increases assembly time and effort due to their smaller dimensions relative to the pallet, necessitating daisy chaining for sequential drawing by a dunnage conversion machine.
Innovation Solution
A palletized unit with a deck supporting a stack of fan-folded stock material, where the stack length is aligned with the deck length and has an aspect ratio less than 3:2, allowing for efficient alignment and reduced need for connecting stacks, thereby facilitating a continuous feed to the dunnage conversion machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple fan-folded paper stacks are placed on a pallet to match pallet dimensions, then the pallet can be fully utilized, but the stacks must be connected by daisy chaining which increases assembly time and effort
Solution Approach 1:
The paper stack is segmented into multiple plies (first ply and second ply) that are superimposed on each other, with each ply having corresponding folds. This segmentation allows the stack to maintain a compact form while providing multiple continuous paper paths, eliminating the need to connect multiple separate stacks through daisy chaining.
Solution Approach 2:
The invention transitions from a two-dimensional arrangement of multiple stacks on a pallet to a three-dimensional stacked configuration where plies are superimposed vertically. The stack length is optimized to be greater than 70% of the deck length, utilizing the vertical dimension to accommodate multiple plies while maintaining a single-stack footprint on the pallet.
2Reliability
If multiple stacks are connected by daisy chaining to enable sequential drawing, then continuous feed is achieved, but the complexity of connecting stacks increases
Solution Approach 1:
The plies are pre-folded and superimposed on each other in a fan-folded configuration before being placed on the pallet. The folds are pre-formed at regular intervals along the length of each ply, creating ready-to-draw sections. This preliminary preparation eliminates the need for complex daisy chaining connections during assembly, as the continuous feed is inherently built into the stacked ply structure.
3Ease of manufacture
If the stack length is increased to reduce the number of stacks needed, then assembly is simplified, but the stack may become unstable
Solution Approach 1:
The aspect ratio of the stack (stack width to stack length) is optimized to be less than 3:2, with the stack length being greater than 70% of the deck length. This parameter optimization ensures that the stack is long enough to reduce the number of stacks needed on the pallet, while maintaining dimensional proportions that enhance stability during handling and operation.
Data Source
AI summary
Palletized units of fan-folded stock material include a pallet having a deck configured to support the fan-folded stock material, and a stack of the stock material supportively positioned on the deck. The stock material includes an elongated web of sheet material configuration defined by folds in the web about fold lines that extend in a transverse direction of the web that segment the web into a plurality of sheet sections, with adjacent sheet sections folded onto one another.