Slit-sheet dunnage with reinforcement ties
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Solution Overview
Problem
Existing slit-sheet stock materials face issues with tearing during winding and expansion due to inadequate control over slit opening, leading to inefficiencies in the production and use of dunnage conversion systems.
Innovation Solution
The improved slit-sheet stock material incorporates transversely-extending rows of slits with un-slit reinforcement ties that temporarily restrict slit opening, preventing tearing during winding and controlling expansion in dunnage conversion systems, featuring a dunnage conversion system with opposed rollers for breaking and opening the slits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If slit-sheet stock material is wound into roll form for subsequent expansion, then the material can be stored and transported efficiently, but the slits may open during winding causing tearing of the material
Solution Approach 1:
The reinforcement ties are incorporated into the slit-sheet material before winding occurs. These ties preliminarily strengthen the material at critical slit locations, preventing tearing during the subsequent winding operation. The reinforcement ties are positioned to bridge slits and provide structural support during the winding process into roll form.
2Ease of operation
If tension is applied to open the slits for expansion, then the material expands to provide cushioning and void-fill functionality, but the sheet material may tear under tension
Solution Approach 1:
The reinforcement ties are pre-installed at strategic locations within the slits to strengthen the material before expansion occurs. During the expansion process, when tension is applied to open the slits, the reinforcement ties prevent the material from tearing by providing structural support at the most vulnerable points. After expansion is complete, the reinforcement ties can be removed or remain as non-interfering elements.
Solution Approach 2:
The reinforcement ties temporarily change the mechanical parameters of the slit-sheet material by increasing its strength and tear resistance during the expansion process. The ties modify the stress distribution within the material, allowing tension to be applied for slit opening without causing failure. Once expansion is achieved, the reinforcement ties may be removed or their function becomes less critical.
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
This solution minimizes tearing and jamming during production and expansion, ensuring efficient conversion of slit-sheet stock material into an expanded dunnage product with reduced density, suitable for packaging applications.
Implementation Method 1
the slit-sheet material has been configured to aid in controlling, such as restricting, opening of a plurality of slits of the slit-sheet stock material, to thereby minimize or prevent tearing... sufficient strength of the sheet material under tension to avoid tearing
Implementation Method 2
a dunnage conversion system with opposed rollers for breaking and opening the slits
Implementation Method 3
When the slit-sheet material is stretched in a direction transverse the direction of the slits, the material deforms, increasing in length and thickness. This stretching and increase in thickness of the slit-sheet material packing material is referred to as expansion.
Data Source
AI summary
An improved expandable slit-sheet stock material is configured to aid in temporarily restricting opening of a plurality of slits of the slit-sheet stock material, such as during winding of the unexpanded stock material or during expansion of the stock material. Each slit of the plurality of slits includes one or more un-slit reinforcement portions, such as reinforcement ties, extending fully between opposite longitudinal sides of the slit, and disposed between opposed transverse endpoints of the slit. The reinforcement ties minimize or prevent tearing of the stock material during the winding or expansion. A dunnage conversion system for expanding the slit-sheet stock material includes an expander having a pair of opposed rollers. The rollers engage the stock material to effect breaking of the un-slit reinforcement portions and expansion of the slit-sheet stock material.