Segmented Perforation Web for Dunnage Separation
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Solution Overview
Problem
Existing dunnage units formed from preformed plastic webs are difficult to separate due to continuous lines of perforations, leading to inefficient separation and potential wrinkles during inflation, which can compromise the sealing process and introduce undesirable stresses.
Innovation Solution
A plastic web with interconnected pouches featuring a gap forming area between adjacent pouches, where the frangible connection at the inflation edge and hermetic seal at the opposite edge allow for easier separation and reduced stresses during inflation, facilitating fuller inflation and a more reliable seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If continuous lines of perforations are used to connect adjacent dunnage units, then the structural integrity of the web is maintained, but the separation of adjacent units becomes difficult and time-consuming
Solution Approach 1:
The continuous line of perforations is divided into spaced-apart segments, creating discrete connection points rather than a continuous connection. This segmentation allows workers to easily separate adjacent dunnage units by pulling at the gaps between perforation lines, dramatically reducing separation time while maintaining structural integrity during inflation and handling.
2Reliability
If continuous lines of perforations connect adjacent pouches, then the web remains structurally sound, but wrinkles can form during inflation that compromise sealing
Solution Approach 1:
By segmenting the perforation lines into spaced-apart connections, the web is allowed to expand more freely during inflation without creating excessive tension in continuous lines. This reduces the formation of wrinkles at seal locations, ensuring reliable sealing while maintaining structural integrity through the distributed perforation connections.
3Strength
If continuous perforation lines are used to connect pouches, then the web maintains strength, but undesirable stresses are introduced during inflation
Solution Approach 1:
The continuous perforation lines are segmented into spaced-apart connections, which distribute the inflation stresses across multiple discrete points rather than concentrating them along continuous lines. This segmentation maintains overall web strength while reducing undesirable stress concentrations that could lead to failure or deformation during the inflation process.
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 solution enables easier and more efficient separation of dunnage units by creating a gap between adjacent pouches, reducing undesirable stresses and ensuring a stronger, leak-resistant seal during the conversion to fluid-filled units.
Implementation Method 1
The frangible connection at the inflation edge is configured to break when engaged by a blunt surface
Implementation Method 2
Air is provided into each pouch from a position slightly upstream of the closing location to maintain inflation of the pouch
Implementation Method 3
an opposite edge seal that extends along the opposite edge and that hermetically seals the inflated pouch
Data Source
AI summary
A preformed web and a method of producing dunnage units from the preformed web. The web is an elongate flattened thermoplastic tube having an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. In one embodiment, the web is configured such that a gap forms between each pair of adjacent pouches when the pouches are inflated. In one embodiment, an inflation edge of the web comprises a frangible connection that allows the inflation edge to be broken by an unsharpened object.