Two-Ply Sheet Stock Splicing with Pre-Adhesive Liners

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Solution Overview

Problem

Existing methods for splicing new two-ply sheet stock material into dunnage conversion machines are cumbersome, requiring sequential attachment of adhesive strips and careful ply alignment, which complicates the process and can lead to feeding issues.

Innovation Solution

A supply of two-ply sheet stock material with pre-applied adhesive layers on opposing surfaces, where the leading ends are temporarily secured together and covered with a removable liner, allowing for easy splicing without sequence limitations, enabling the plies to be attached directly to the trailing ends of the almost-spent supply during machine operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pre-applied adhesive layers with removable liners are used on two-ply sheet stock material, then the splicing process is simplified and operator error is reduced, but the manufacturing complexity of the sheet stock material increases

Engineering Contradiction:

Improvesplicing processVSAvoidsheet stock material structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Adhesive layers are pre-applied to the sheet stock material during manufacturing, and removable liners are pre-attached to protect the adhesive. This preliminary preparation eliminates the need for operators to apply adhesive during splicing, simplifying the operation while the added manufacturing steps increase production complexity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A removable liner acts as an intermediary between the adhesive layer and the external environment. The liner protects the adhesive during storage and handling, and is removed only when splicing is needed. This intermediary component simplifies operator interaction with the adhesive while adding structural complexity to the material

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If sequential ply alignment and adhesive strip application is required, then precise ply attachment is achieved, but the splicing time and operational complexity increase

Engineering Contradiction:

Improveply alignmentVSAvoidsplicing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The adhesive layers are pre-positioned on both plies during manufacturing, merging the adhesive application step with the material production process. This eliminates the need for separate adhesive application during splicing, reducing time while the pre-positioning ensures precise alignment is maintained

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sheet stock material is designed to be self-aligning through the pre-applied adhesive layers. When the removable liners are removed and the plies are brought together, the pre-positioned adhesive automatically ensures correct alignment without requiring manual adjustment or sequential attachment procedures

Inventive Principle:

Principle #25Self-service

3Reliability

If adhesive is applied to each ply separately with removable coverings, then proper ply sequencing is ensured, but the splicing process becomes more complex and time-consuming

Engineering Contradiction:

Improveply sequencingVSAvoidsplicing procedure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Both plies are equipped with identical pre-applied adhesive layers and removable liners in the same positions. This homogeneity means that either ply can be attached first without affecting the outcome, eliminating sequencing requirements while maintaining reliable attachment. The uniform design simplifies the splicing procedure while ensuring proper ply alignment

Inventive Principle:

Principle #33Homogeneity

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

Simplifies the splicing process by eliminating the need for sequential ply alignment and adhesive strip application, ensuring a seamless transition between new and almost-spent supplies, enhancing operational efficiency and reducing operator error.

Implementation Method 1

Each of the two plies includes an adhesive layer disposed on a corresponding leading end or trailing end

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11661297B2Method of loading a dunnage conversion machine and sheet stock material useful therein

Publication Date: 2023.05.30 RANPAK CORP

AI summary

A supply of stock material for a dunnage conversion machine includes two plies of sheet stock material wound into a roll or fan-folded into a stack. Each ply has disposed on a corresponding leading or trailing end thereof an adhesive layer and a removable release liner covering the adhesive layer. When applied to a leading end of the supply, the adhesive layer is applied to opposing, outwardly-facing surfaces of the respective plies. When a supply of stock material is almost spent, the operator removes the release liners from both plies to expose respective adhesive layers, and then interposes the leading end of a new supply between the plies of the trailing end of the almost-spent supply and presses the layers together to attach the plies of the new supply to respective plies of the almost-spent supply, for conversion into dunnage.