Tear Assist Assembly for Dunnage Separation

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Solution Overview

Problem

Existing dunnage conversion machines face difficulties in manually separating discrete dunnage products, especially when multiple layers are connected without perforations, and semi-automatic or automatic bladed cutting mechanisms are costly and cumbersome.

Innovation Solution

A dunnage conversion machine equipped with a tear assist assembly that includes a pinch arm and a stop, controlled by a controller to create a tear in the dunnage strip without using a cutting blade, allowing for easy separation of discrete dunnage products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual tearing is used to separate discrete dunnage products, then the separation process is simple and inexpensive, but it becomes difficult when multiple layers are connected without perforations

Engineering Contradiction:

Improvesimplicity of separation processVSAvoiddifficulty of tearing multi-layer dunnage

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The system performs preliminary action by creating a controlled tear in the multi-layer dunnage structure before manual separation is required. The tear assist assembly includes a pinch arm that captures the dunnage strip and a reverse feed mechanism that creates a controlled tear at a predetermined location, enabling easy manual separation afterward.

Inventive Principle:

Principle #10Preliminary action

2Extent of automation

If semi-automatic or automatic bladed cutting mechanisms are used to separate discrete dunnage products, then the separation process is automated and reliable, but the machinery becomes large, heavy, and expensive

Engineering Contradiction:

Improveautomation of separation processVSAvoidsize and cost of cutting mechanism

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The invention extracts the essential function of automated separation without using expensive bladed cutting mechanisms. The tear assist assembly uses a pinch arm with reverse feed capability to create controlled tears, eliminating the need for heavy cutting blades while maintaining automated separation functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system replaces expensive, heavy bladed cutting mechanisms with a simpler, more affordable tear assist assembly that uses a pinch arm and controlled reverse feeding. This cheaper mechanism achieves the same separation function without the complexity and cost of traditional cutting systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If bladed cutting mechanisms are used to separate dunnage products, then separation is reliable and automated, but the machinery becomes heavy and expensive to incorporate

Engineering Contradiction:

Improvereliability of separationVSAvoidweight of dunnage conversion machine

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The invention replaces the heavy mechanical bladed cutting system with a lighter tear assist mechanism that uses a pinch arm and controlled reverse feeding. This substitution maintains reliable separation while significantly reducing the weight and complexity of the machinery.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables efficient and cost-effective separation of discrete dunnage products from the dunnage conversion machine, reducing the need for expensive cutting blades and simplifying the manual separation process.

Implementation Method 1

The pinch arm is movable between a resting position in which the pinch arm is located on the one side of and out of the path, and a pinching position in which the pinch arm is located in the path to capture the strip of dunnage between the pinch arm and the stop

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

The feeding assembly downstream of the forming assembly is configured to pull the sheet stock material from a supply, through the forming assembly, and to advance the strip of dunnage along a path in a downstream direction

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 3

a forming assembly for forming sheet stock material into a strip of dunnage

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

form a sheet stock material into a strip of dunnage having a lower density than the sheet stock material

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS12179454B2Dunnage conversion machine and method with assisted tear apparatus

Publication Date: 2024.12.31 RANPAK CORP

AI summary

A dunnage conversion machine includes a forming assembly configured to form a sheet stock material into a strip of dunnage, and a feeding assembly downstream of the forming assembly that is configured to pull the sheet stock material through the forming assembly. The machine also includes a tear assist assembly downstream of the feeding assembly that includes a pinch arm on one side of the path and a stop opposing the pinch arm on an opposite side of the path. The pinch arm is movable between a resting position in which the pinch arm is located on the one side of the path, and a pinching position in which the pinch arm is located in the path to capture the strip of dunnage between the pinch arm and the stop. Reversing the feed assembly while the pinch arm is in the pinching position causes the strip of dunnage to tear.