Splice Member for Stock Material Units in Dunnage Conversion
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Solution Overview
Problem
Current dunnage conversion systems face challenges in efficiently processing and connecting stock material units to form a continuous feed for dunnage conversion machines, particularly in ensuring seamless integration and minimizing material waste during the conversion process.
Innovation Solution
The introduction of a stock material unit with a tapered sheet section and a splice member, featuring a base with a larger area and a connector with adhesive properties, allows for secure daisy-chaining of units by non-removably attaching the connector to the tapered sheet section and removably attaching it to the base, facilitating efficient connection and continuous feeding into the dunnage conversion machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stock material units are connected using a splice member with adhesive, then the connection strength and continuity are improved, but the device complexity increases due to the additional components (base, connector, adhesive layers)
Solution Approach 1:
The splice member is divided into distinct functional segments: a base portion attached to the tapered sheet section and a connector portion that interfaces with the dunnage conversion machine. This segmentation allows each part to be optimized independently while maintaining overall connection reliability.
Solution Approach 2:
The splice member acts as an intermediary component between stock material units, providing a reliable connection mechanism. The adhesive layers serve as mediators that bond the connector to both the tapered sheet section and the machine interface, ensuring strong attachment without requiring complex mechanical fastening systems.
2Adaptability or versatility
If a tapered sheet section with multiple folds is used, then the adaptability and ease of connection are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The tapered sheet section is pre-formed with multiple folds and attachments during the stock material unit manufacturing process. This preliminary action ensures that the connection interface is ready in advance, allowing for easier and faster connection operations without requiring complex real-time adjustments during assembly.
Solution Approach 2:
The tapered sheet section features an asymmetric geometry with a gradual taper that transitions from a wider base to a narrower tip. This asymmetric design provides natural alignment cues and facilitates directional insertion into the connector, improving ease of connection while the fold patterns are designed to accommodate reasonable manufacturing tolerances.
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 enables efficient processing and connection of stock material units, reducing material waste and ensuring a continuous feed, thereby enhancing the operational efficiency of dunnage conversion systems.
Implementation Method 1
a first adhesive layer positioned on the base and having a first surface area, and a second adhesive layer positioned on the connector and having a second surface area that is less than the first surface area
Data Source
AI summary
Stock material units that may be used in a dunnage conversion machine. For example, stock material units include sheet material that may be fed into the dunnage conversion machine and may be converted thereby into dunnage.