Polygonal Dunnage Conversion Machine Yield
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Solution Overview
Problem
Existing dunnage products do not efficiently utilize sheet stock material to fill void volumes in shipping containers, leading to suboptimal cushioning and protection of packaged items.
Innovation Solution
A dunnage conversion machine that converts sheet stock material into a dunnage product with a polygonal cross-section, such as a triangular shape, by rolling and crumpling the material to form a tubular shape with a tab and ridge structure, enhancing yield and cushioning properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional dunnage products are used to fill void volumes in shipping containers, then the void volume is filled, but the yield (volume occupied per unit area of sheet stock material) is suboptimal
Solution Approach 1:
The patent applies curvature by transforming flat sheet stock material into a three-dimensional tubular shape with curved surfaces. The forming assembly rolls and crumples the material to create a tubular configuration that occupies greater volume compared to flat or simply folded structures, thereby improving yield without increasing material area
Solution Approach 2:
The invention transitions from two-dimensional sheet stock material to a three-dimensional tubular structure with complex spatial configuration. By creating a tubular shape with radial and longitudinal dimensions, the material occupies significantly more volume in three-dimensional space, directly addressing the yield improvement goal
2Strength
If sheet stock material is converted into traditional dunnage products, then dunnage products are produced, but cushioning properties are insufficient
Solution Approach 1:
The patent applies local quality by creating heterogeneous structural features within the tubular dunnage product. The forming assembly produces variations in wall thickness, density, and crumpling patterns at different locations along the tube, with thicker and more densely crumpled regions providing enhanced cushioning where needed while maintaining overall structural integrity
Solution Approach 2:
The curved and crumpled tubular structure creates multiple compression surfaces and air pockets that enhance cushioning properties. The three-dimensional curved geometry distributes impact forces more effectively compared to flat structures, improving protection while maintaining a relatively simple manufacturing process
Data Source
AI summary
A machine for converting a sheet material into a relatively less dense dunnage product includes a forming assembly and a feeding assembly downstream of the forming assembly. The forming assembly is configured to cause lateral edges of the sheet material to roll towards one another, forming a tubular shape. A deflector at a downstream end of the forming assembly is configured to engage the lateral edges of the sheet material and to urge the lateral edges into an interior of the tubular shape. This juxtaposes lateral edge portions of the sheet material adjacent the respective lateral edges. A forming channel at a downstream end of the forming assembly faces the deflector to receive the lateral edge portions and shape them into a tab. Finally, the feeding assembly includes rotating connecting members that engage and connect together the overlapping lateral edge portions of the sheet material forming the tab.