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HK1110272A - Stand for dunnage conversion machine and dunnage conversion system - Google Patents

Stand for dunnage conversion machine and dunnage conversion system Download PDF

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Publication number
HK1110272A
HK1110272A HK08101086.5A HK08101086A HK1110272A HK 1110272 A HK1110272 A HK 1110272A HK 08101086 A HK08101086 A HK 08101086A HK 1110272 A HK1110272 A HK 1110272A
Authority
HK
Hong Kong
Prior art keywords
stock material
sheet stock
stack
dunnage conversion
dunnage
Prior art date
Application number
HK08101086.5A
Other languages
Chinese (zh)
Other versions
HK1110272B (en
Inventor
J. Harding Joseph
L. Skiba Judith
James A. Simmons, Jr
Cheich Robert
Tekavec James
W. Lintala Edward
Coppus Dan
P.M. Demers Raymond
H.M. Kuypers Koen
Methorst Erwin
Kobben Pierre
Original Assignee
Ranpak Corp.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ranpak Corp. filed Critical Ranpak Corp.
Publication of HK1110272A publication Critical patent/HK1110272A/en
Publication of HK1110272B publication Critical patent/HK1110272B/en

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Description

Dunnage conversion machine stand and dunnage conversion system
The application is a divisional application of an invention patent application with the original application date of 2003, month 4 and day 22, the application number of 03814644.4(PCT/US03/12301) and the invention name of a dunnage conversion machine system.
Technical Field
The present invention relates to a dunnage conversion machine, and more particularly, to a dunnage conversion machine and fan-folded stock material therefor that enables improved loading of the stock material.
Background
A cushioning conversion machine converts sheet stock material into a relatively dense strip of dunnage product that can be used to provide cushioning in a package. Typically, the conversion machine is mounted on a stand so that the conversion machine is at a height at which the dunnage product produced by the machine is readily accessible, such as at the eye level of an operator. Some converter stands have the ability to tilt the converter relative to the horizontal while others enable the converter to rotate in the horizontal plane.
In these prior art converting machines, sheet stock material is pulled from a supply, such as a roll of sheet stock material or a stack of fan-folded sheet stock material, to the upstream end of the machine. While the sheet stock material often follows a consistent path as it travels from the supply to the upstream end of the machine, the sheet stock material may experience undulations or undulations when the converting machine is operating at higher speeds, such as when empty fill products are being produced, or during start-up and shut-down of the machine. Sometimes, these fluctuations can cause tearing to begin in the lateral edge portions of the sheet stock material, which can cause machine jams or cause detrimental effects on the quality of the dunnage product.
Other machines are constructed in a manner that prevents access to components within the machine, for example, for assembly or servicing of the components, due to the particular orientation of the machine or the complexity of the mounting arrangement of the components therein.
Various packaging systems have also been developed in which access to a dunnage conversion machine, such as a system, is impeded by the particular arrangement of the system.
Accordingly, there is a need for a dunnage conversion machine and stand, as well as an improved packaging system, that can achieve stock material guiding features in the stand, that are easily accessible and can service components within the machine and/or system, and that improve ergonomics in such machines and/or systems.
Disclosure of Invention
The present invention provides a packaging system having easy access to its components. According to one general aspect of the invention, a stand directs sheet stock material to a dunnage conversion machine. In accordance with another aspect of the invention, an infeed paper guide assembly of a dunnage conversion machine guides sheet stock material from a stock supply and through the dunnage conversion machine. In accordance with another general aspect of the invention, the pulling assembly motor and severing assembly motor are placed in an L-shaped configuration to support a dunnage conversion machine having a compact configuration.
More particularly and in accordance with one aspect of the present invention, a stand for a dunnage conversion machine is provided that includes a base and a pair of upright guide members. An upright guide member is mounted on the base and supports the dunnage conversion machine at an upper end thereof.
The guide members define a channel therebetween for guiding sheet stock material to the dunnage conversion machine.
According to another aspect of the invention, a dunnage conversion machine is provided that includes a conversion sub-assembly and an infeed paper guide assembly. The conversion sub-assembly converts sheet stock material into a dunnage product. The infeed paper guide assembly is located upstream of the converting sub-assembly. The feed paper guide assembly is movable between an open position in which a portion of the travel path of the sheet stock material is accessible, and a closed position in which the feed paper guide assembly guides the sheet stock material along the travel path.
In accordance with another aspect of the invention, a dunnage conversion machine is provided that includes a pulling assembly, a severing assembly, and a frame having an L-shaped configuration. The pulling assembly pulls sheet stock material through the dunnage conversion machine, thereby converting the sheet stock material into a strip of dunnage. The pulling assembly is powered by a pulling assembly motor having a pulling assembly motor axis. The cutting assembly cuts the strip of dunnage into a dunnage product. The severing assembly is powered by a severing assembly motor having a severing assembly motor axis. The pulling assembly motor is mounted on the frame so that its axis is parallel to one leg of the L-shaped structure, and the severing assembly motor is mounted on the frame so that its axis is parallel to the other leg of the L-shaped structure.
According to another aspect of the invention, a packaging system is provided that includes a dunnage conversion machine and a packaging surface. The dunnage conversion machine is positioned above the packaging surface.
According to another aspect of the invention, a packaging system is provided that includes a dunnage conversion machine, a stock supply assembly, and a aisle. The stock supply assembly supplies sheet stock material to the dunnage conversion machine. The aisle provides access to the ingredient supply assembly.
In accordance with another aspect of the invention, a packaging system is provided that includes a high support member, a dunnage conversion machine, and a stock supply assembly. The dunnage conversion machine is mounted to the upper support member such that the dunnage conversion machine is suspended from the upper support member. The stock supply assembly supplies sheet stock material to the dunnage conversion machine.
In accordance with another aspect of the invention, a dunnage conversion system is provided that includes a dunnage conversion machine and a stand. The stand supports a dunnage conversion machine that draws sheet stock material from a stack of sheet stock material and converts it into a strip of dunnage product, and supports the stack of sheet stock material below the dunnage conversion machine. The bracket includes a pair of laterally spaced upright channel members having longitudinally extending, laterally spaced left and right inwardly facing walls and laterally extending, longitudinally spaced front and rear guide walls extending inwardly from the inwardly facing guide walls. The width between the left and right sides of the stack of sheet stock material is greater than the distance between the inner edges of the guide walls but less than the distance between the inward-facing walls of the bracket, and the distance between the front and rear sides of the stack of sheet stock material is less than the distance between the front and rear guide walls of the bracket. The stack of sheet stock material is supported between the upright channel members and the upright channel members guide the sheet stock material to the dunnage conversion machine as the dunnage conversion machine draws sheet stock material therefrom.
According to another aspect of the invention, there is provided a method for loading a stack of rectangular sheet stock material into a stand for a dunnage conversion machine, wherein the stand has a pair of laterally spaced upright channel members having laterally spaced left and right inwardly facing walls extending in a longitudinal direction and laterally extending front and rear longitudinally spaced guide walls extending inwardly from the inwardly facing guide walls, and wherein a width between the left and right sides of the stack is greater than a distance between inner edges of the guide walls but less than a distance between the inwardly facing walls of the stand, and the distance between the front and rear sides of the stack is less than the distance between the front and rear guide walls of the stand, the method comprising the steps of: inserting the left or right side of the stack between the guide members, tilting the stack so that its first and second diagonally opposed corners are located between the inwardly facing walls of the bracket, moving the left or right side of the stack towards the respective left or right inwardly facing walls of the bracket, tilting the stack so that the left and right sides of the stack are disposed within the respective left and right walls of the bracket, moving the stack laterally towards the left or right inwardly facing walls so that the stack is substantially centered between the inwardly facing walls.
In accordance with another aspect of the invention, a dunnage conversion system is provided that includes a dunnage conversion machine and a stand. The dunnage conversion machine converts sheet stock material into a dunnage product and includes a pulling assembly for pulling the sheet stock material into the dunnage conversion machine and an outlet through which the dunnage product is discharged. The dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the outlet of the dunnage conversion machine is toward the front of the system, and one or more servicing/loading positions in which the feed end of the pulling assembly is toward the front of the system for easy access by an operator.
In accordance with another aspect of the invention, a dunnage conversion system is provided that includes a dunnage conversion machine and a stand. The dunnage conversion machine converts sheet stock material into a dunnage product and includes a severing assembly for severing a strip of dunnage into a desired length and a cover for covering the severing assembly. The bracket includes a pair of upright guide members. The width of the upright guide member is greater than the width of the cover. The dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the dunnage conversion machine discharges a strip of dunnage at the front of the system, and one or more servicing/loading positions in which the cover of the severing assembly is disposed between the upright guide members.
In accordance with another aspect of the invention, a dunnage conversion system is provided that includes a dunnage conversion machine and a stand. A dunnage conversion machine converts sheet stock material into a dunnage product. The dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the dunnage conversion machine is in an upright position and one or more servicing/loading positions in which the dunnage conversion machine is at least partially inverted.
In accordance with another aspect of the invention, a baled stack of sheet stock material for use with a dunnage conversion machine is provided. The baled stack includes a stack of fan-folded sheet stock material and a jacket for at least partially surrounding the stack. At least one packing rope secures the jacket to the stack of sheet stock material.
In accordance with another aspect of the invention, a nested stack of sheet stock material for use with a dunnage conversion machine is provided. The nested stack comprises a stack of fan-folded sheet stock material and a jacket having bottom tabs located beneath the stack and movable away from each other to enable the tabs to be removed from beneath the stack.
In accordance with another aspect of the invention, a stack of sheet stock material for use with a dunnage conversion machine is provided. The stack comprises a stack of fan-folded sheet stock material having a top and a bottom, an adhesive layer located at least on the top or bottom of the stack, and a release liner covering the adhesive layer.
According to another aspect of the present invention, there is provided a method for loading a stack of sheet stock material onto a second stack of sheet stock material, comprising the steps of: providing first and second stacks of sheet stock material with a layer of adhesive applied to the top of the first stack or the bottom of the second stack, and placing the second stack on top of the first stack, whereby the adhesive bonds the top page of the first stack to the bottom page of the second stack.
According to another aspect of the present invention, there is provided a method for loading a stack of sheet stock material onto a second stack of sheet stock material, comprising the steps of: providing first and second stacks of sheet stock material with an adhesive layer applied to the top of the first stack or the bottom of the second stack and a release liner covering the adhesive layer, placing the second stack on top of the first stack, and pulling the release liner from between the stacked stacks of sheet stock material to expose the adhesive layer, whereby the adhesive bonds the top page of the first stack to the bottom page of the second stack.
In accordance with another aspect of the invention, a baled stack of sheet stock material for use with a dunnage conversion machine is provided. The stack comprises a stack of fan-folded sheet stock material; an outer sleeve having at least two baffles defining an L-shaped cross-section, a corner of the stack being positioned adjacent a corner of the L-shaped outer sleeve; and at least one baling rope for securing the outer cover to the stack of sheet stock material.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet stock material into a dunnage product is provided. Such machines include a forming assembly for forming sheet stock material into a continuous strip of dunnage; a pulling assembly downstream of the forming assembly for advancing the sheet material through the forming assembly; wherein the forming assembly includes a funnel portion through which the sheet stock material passes to form the sheet stock material into a strip of dunnage and to direct the formed strip toward the pulling assembly.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet stock material into a dunnage product is provided. Such machines include a forming assembly for forming sheet stock material into a continuous strip of dunnage; a pulling assembly downstream of the forming assembly for advancing the sheet material through the forming assembly; wherein the forming assembly includes a plurality of rollers in an endless array through which the sheet stock material passes to form the sheet stock material into a strip of dunnage and to direct the formed strip toward the pulling assembly.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet stock material into a dunnage product is provided. The machine includes first and second pulling assemblies, each pulling assembly including at least two grippers moveable together relative to each other through the dunnage transfer region and cooperating to grasp the sheet stock material therebetween to advance the sheet stock material through the transfer region, and at least one of the grippers including an aperture for collecting and laterally capturing the sheet stock material therein as the gripper moves through the transfer region; wherein the first pulling assembly is located downstream of the forming assembly and the second pulling assembly is located downstream of the first pulling assembly; and wherein the first pulling assembly operates at a different speed than the second pulling assembly to longitudinally crumple the strip of dunnage passing through the dunnage transfer area.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet material into a dunnage product is provided. Such machines include a pulling assembly for advancing sheet material through the machine; the pulling assembly includes at least two opposed jaws, at least one of which is movable relative to the other jaws through the dunnage transfer region and cooperates to grasp the sheet stock material therebetween to advance the sheet stock material through the transfer region, and the moving jaws include apertures for collecting and laterally capturing the sheet stock material therein as the jaws move through the transfer region; wherein the moving jaw with the hole includes a plurality of projections projecting from an inner edge thereof to assist in gripping the sheet stock material.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet material into a dunnage product is provided. Such machines include a pulling assembly for advancing sheet material through the machine; the pulling assembly includes a pair of rotatable transfer members each having a concave outer surface and a plurality of projecting elements extending from the concave outer surface, the transfer members being opposed to each other to define a dunnage transfer region therebetween and cooperating upon rotation to collect and laterally capture sheet material therebetween and advance the sheet material through the transfer region.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet material into a dunnage product is provided. Such machines include a pulling assembly for advancing sheet material through the machine; the pulling assembly includes a pair of rotatable transfer members each having a cylindrical outer surface and a plurality of projecting elements extending from the cylindrical surface, the transfer members being opposed to each other to define a dunnage transfer region therebetween and cooperating upon rotation to collect and laterally capture sheet material therebetween and advance the sheet material through the transfer region.
In accordance with another aspect of the invention, a dunnage conversion machine is provided for converting sheet material, at least two layers of which are folded flat along their lengths and joined together along fold edges, into a dunnage product. Such machines include a pulling assembly for advancing a flat sheet material through the machine; expanding means for separating adjacent layers of flat-folded sheet material from one another as the flat-folded sheet material passes therethrough to form an expanded strip of sheet material; the pulling assembly includes at least two grippers movable together relative to each other through the transfer zone and cooperating to grasp the expanded strip of sheet material therebetween to advance the expanded strip of sheet material through the transfer zone, and at least one of the grippers includes an aperture for collecting and laterally capturing the expanded strip of sheet material therein as the gripper moves through the transfer zone.
According to another aspect of the invention, a method is provided for converting a sheet material into a dunnage product, at least two layers of the sheet material being folded flat along their length and joined together along a hem. This method comprises the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the flat-folded sheet material comprises moving the jaws together relative to each other across the transfer region to cooperatively grasp the flat-folded sheet material therebetween and advance the flat-folded sheet material through the transfer region while the apertures in at least one of the jaws collect and laterally capture the flat-folded sheet material therein as the jaws move across the transfer region.
In accordance with another aspect of the present invention, a dunnage conversion machine for converting sheet material into a dunnage product is provided. Such machines include a pulling assembly for advancing sheet material through the machine; the pulling assembly includes at least two grippers movable together relative to each other across the transfer area and cooperating to grasp the strip of dunnage therebetween to advance the strip of dunnage through the transfer area, and at least one of the grippers includes an aperture for collecting and laterally capturing the strip of dunnage therein as the gripper moves across the transfer area; and a software controller for controlling the speed of the pulling assembly.
In accordance with another aspect of the invention, a method for converting sheet material into a dunnage product is provided. This method comprises the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising ramping up the speed of the pulling assembly prior to initiating the conversion process.
In accordance with another aspect of the invention, a method for converting sheet material into a dunnage product is provided. This method comprises the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising ramping down the speed of the pulling assembly after completing the conversion process.
In accordance with another aspect of the invention, a method for converting sheet material into a dunnage product is provided. This method comprises the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising adjusting the speed of the pulling assembly to one of a plurality of preprogrammed speeds prior to using the pulling assembly to advance the sheet material through the machine.
In accordance with another aspect of the invention, a method for converting sheet material into a dunnage product is provided. This method comprises the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising operating the pulling assembly at a first speed; and operating the pulling assembly at a second speed.
Drawings
The following figures are attached to and form part of the present invention.
FIG. 1 is a front perspective view of a dunnage conversion machine and stand in accordance with the present invention.
FIG. 2 is a rear perspective view of the dunnage conversion machine and stand of FIG. 1.
Fig. 3 is a front perspective view of the bracket of fig. 1.
FIG. 4 is an exploded front perspective view of the bracket of FIG. 1 showing the various components that make up the bracket in greater detail.
FIG. 5 is a perspective view of a stock supply in the form of a stack of fan-folded sheet stock material for use in the dunnage conversion machine and stand of FIG. 1.
FIG. 6 is a front perspective view of the dunnage conversion machine and stand of FIG. 1, with the dunnage conversion machine shown pivoted to a servicing/loading position and with the cover of the dunnage conversion machine removed to view the various components of the machine.
FIG. 7 is a rear perspective view of the dunnage conversion machine and upper portion of the stand of FIG. 1, with the hood and opening guide plate of the conversion machine shown in an open position.
FIG. 8 is a side view of the dunnage conversion machine of FIG. 1, showing the internal components of the machine, and showing the frame, cover, and hood of the conversion machine in phantom lines.
FIG. 9 is a right side perspective view of the dunnage conversion machine of FIG. 1, with its hood in an open position to allow viewing of the internal components of the machine.
FIG. 10 is a left side perspective view of the dunnage conversion machine of FIG. 1, with its hood in an open position to allow viewing of the internal components of the machine.
FIG. 11 is a perspective view of a pulling mechanism of the dunnage conversion machine of FIG. 1, the pulling mechanism shown mounted to a frame of the dunnage conversion machine.
FIG. 12 is a top view of a pulling assembly of the dunnage conversion machine of FIG. 1.
FIG. 13 is an end view of the pulling mechanism and compression members of FIG. 11 as viewed from the upstream end of the dunnage conversion machine.
FIG. 14 is an end view of a severing assembly of the dunnage conversion machine of FIG. 1.
Fig. 15 is a perspective view of the severing assembly of fig. 14.
FIG. 16 is a perspective view of a portion of an output chute and severing assembly of the dunnage conversion machine, as viewed from a downstream end of the dunnage conversion machine.
FIG. 17 is a side view of a packaging system including a dunnage conversion machine in accordance with the present invention.
FIG. 18 is a perspective view of a packaging system including a dunnage conversion machine in accordance with the present invention.
FIG. 19 is a perspective view of another packaging system including a dunnage conversion machine in accordance with the present invention.
FIG. 20 is a front perspective view of a dunnage conversion machine and stand in accordance with another embodiment of the present invention.
Fig. 21 is a front perspective view of the bracket of fig. 20.
Fig. 22-26 sequentially illustrate several views of an exemplary method for inserting a stack of fan-folded sheet stock material into the stand of fig. 20 and 21.
FIG. 27 is a front perspective view of the dunnage conversion machine and upper portion of the stand of FIGS. 20 and 21, with the dunnage conversion machine shown pivoted to a servicing/loading position, and with the cover of the dunnage conversion machine positioned between a pair of upright guide members of the stand and thus hidden from view.
FIG. 28 is a front perspective view of the dunnage conversion machine and upper portion of the stand of FIGS. 20 and 21, with the dunnage conversion machine shown pivoted to a servicing/loading position, and with the cover of the dunnage conversion machine positioned between a pair of upright guide members of the stand and thus not visible in the figures, and with the hood of the conversion machine shown in an open position.
FIG. 29 is a perspective view of a mounting mechanism that enables the dunnage conversion machine to selectively pivot relative to the stand from an operating position to a service/rotator position.
FIG. 30 is a side view of the mounting mechanism of FIG. 29 showing the position of the mechanism when the dunnage conversion machine is in an operating position.
FIG. 31 is a side view of the mounting mechanism of FIG. 29 showing the position of the mechanism when the dunnage conversion machine is in a servicing/loading position.
FIG. 32 is a perspective view of a baled stack of sheet stock material in accordance with the present invention.
Fig. 33 is a side view of the baled stack of fig. 32 as viewed from line 33-33 in fig. 32.
Fig. 34 is a bottom perspective view of the baled stack of fig. 32.
Fig. 35 is a bottom perspective view of a stack of sheet stock material forming a portion of the baled stack of fig. 32.
FIG. 36 is a perspective view of a baled stack of sheet stock material in accordance with another embodiment of the present invention.
Fig. 37 is a side view of the baled stack of fig. 36 as viewed from line 37-37 in fig. 36.
FIG. 38 is a perspective view of a baled stack of sheet stock material in accordance with another embodiment of the present invention.
FIG. 39 is a bottom perspective view of a stack of sheet stock material in accordance with another embodiment of the present invention.
FIG. 40 is a perspective view of a baled stack of sheet stock material in accordance with another embodiment of the present invention.
FIG. 41 is a schematic perspective view of a pulling mechanism and forming section in accordance with another embodiment of the present invention, wherein sheet stock material is shown passing around a constant entry roller and through the forming section.
FIG. 42 is a schematic perspective view of a pulling mechanism and forming section according to another embodiment of the present invention.
FIG. 43 is a schematic perspective view of a forming section according to another embodiment of the present invention.
FIG. 44 is a schematic perspective view of a pulling mechanism and forming section according to another embodiment of the present invention.
FIG. 45 is a schematic perspective view of a pulling mechanism and forming section according to another embodiment of the present invention.
FIG. 46 is a schematic top view of the compression member and upstream and downstream pulling mechanisms with the sheet stock material shown advancing therethrough.
Fig. 47 is a schematic perspective view of a pulling mechanism according to the present invention.
FIG. 48 is a schematic perspective view of another pulling mechanism according to the present invention.
FIG. 49 is a schematic perspective view of another pulling mechanism according to the present invention.
FIG. 50 is a schematic top view of another pulling mechanism, according to another embodiment of the invention.
Fig. 51 is a schematic front view of the pulling mechanism of fig. 50 as viewed from line 51-51 in fig. 50.
FIG. 52 is a schematic perspective view of a pulling mechanism, forming section and stack of sheet stock material shown passing around a constant entry roller and through the forming section in accordance with another embodiment of the present invention.
FIG. 53 is a schematic perspective view of the pulling mechanism, forming section and stack of sheet stock material of FIG. 49, and an expansion device according to the present invention.
Detailed Description
Referring now in detail to the drawings, and initially to FIGS. 1-4, there is shown a dunnage conversion machine 10 and stand 12 in accordance with the present invention. The dunnage conversion machine 10 converts sheet stock material, such as one or more layers of recyclable and reusable kraft paper, into a strip of dunnage including, for example, a narrow three-dimensional strip or substantially cylindrical rope. The machine 10 has an upstream end 14 and a downstream end 16, with sheet stock material being fed to the machine 10 at the upstream end 14 and the machine 10 discharging dunnage product from the downstream end 16. As used herein, the terms upstream and downstream refer to the path of travel of the sheet stock material as it moves from the stand 12 as a strip of dunnage product to the outlet of the dunnage conversion machine 10, as shown at 15 (fig. 8). Dunnage products are used as environmentally friendly packaging materials, typically as void fillers or cushions during shipping. The stand 12 is generally vertically oriented and includes a base 18 and a pair of upright guide members 22 on which the machine frame is mounted. Each bottom corner of base 18 includes wheels 26 to allow easy movement of stand 12 and machine 10.
The stock supply 27 supplies sheet stock material to the upstream end 14 of the machine 10. In the illustrated embodiment, the stock supply 27 is separate from the machine 10 and includes a stack of fan-folded sheet stock material, as shown in FIG. 5, that rests on the base 18 of the stand 12 between the upright guide members 22.
It should be appreciated that the stock supply 27 may be of any desired type for supplying sheet material to the converting machine 10. For example, the stock supply 27 may alternatively take the form of a roll of sheet stock material mounted on a shaft and suitably supported at its ends by the stand 12. Alternatively, the axles of the stock rolls may be supported on separate carts and placed adjacent or next to the stand 12. The advantage of fan folded sheet stock material over a stock roll of sheet material is that little or no inertia needs to be overcome. In addition, when using fan folded stock material rather than rolled stock material, run speed can be increased and edge tension problems are minimized. Additionally, although in the illustrated embodiment the fan-folded stock material comprises a single ply of sheet material, multi-ply arrangements, such as two-ply or three-ply arrangements, may alternatively be used in the present invention. The number of stacks of sheet material can vary depending on the characteristics of the dunnage conversion machine used and/or the desired quality of the dunnage product produced.
Each upright guide member 22 includes an inner side wall 30, an outer side wall 32 spaced from the inner side wall 30 by a gap G, a front wall 34 and a rear wall 36. The rear wall 36 spans the gap G between the inner and outer side walls 30 and 32 and connects the rear edges thereof. Similarly, the front wall 34 spans the gap G between the inner and outer side walls 30 and 32 and connects to the front edges thereof. The front wall 34 extends inwardly beyond the respective inner side walls 30 to form a pair of respective front guide surfaces 44. The lateral support members 48 are connected to and extend between the guide members 22 at the uppermost ends of the guide members 22.
Referring to fig. 3 and 4, a pair of vertically extending catches 52 are hingedly connected by hinges 54 at or near the corners formed by the respective inner and rear walls 30, 36 of the upright guide member 22. The inner side walls 30 each include a vertical slot or opening 60, the slot or opening 60 being sized to receive the corresponding latch 52 therethrough. The catches 52 are pivotable between an open position in which the catches 52 are retracted into the respective slots 60, and a closed position in which the catches 52 extend inwardly relative to each other such that the rear guide surfaces 64 are positioned opposite the front guide surfaces 44 of the front wall 34. The catch 52 is spring biased to its closed position.
In accordance with the present invention, when a stack of fan-folded sheet stock material (fig. 5) having a width slightly less than the distance between the upright guide channels 22 (and slightly greater than the distance between the innermost edges of the catches 52) and a depth slightly less than the distance between the front and rear guide surfaces 44 and 64 is inserted between the guide members 22 from the rear of the frame 12, the catches 52 deflect outwardly relative to each other and retract into their respective vertical slots 60. This enables the fan-folded sheet stock material to be pushed toward the front guide surface 44 of the guide member 22. Once the stack of fan folded sheet stock material abuts the front guide surface 44, the latch 52 springs back to its original biased position, thereby capturing the stack of fan folded sheet stock material between the front guide surface 44 and the rear guide surface 64. The front and rear guide surfaces 44 and 64 prevent or at least reduce the likelihood of the stack of fan-folded sheet stock material from tipping forward or rearward from the frame 12, while the inner side walls 30 of the respective guide members 22 prevent or at least reduce the likelihood of the stack of fan-folded sheet stock material from moving laterally within the frame 12. This has also been found to be particularly useful when the carriage is moved from one position to another on the wheels 26.
Referring now to FIGS. 3, 4 and 6, the dunnage conversion machine 10 is mounted to the stand 12 by a pair of hinge plates 80. Each hinge plate 80 includes a laterally extending hinge pin 82, the hinge pins 82 being rotatably supported at opposite ends thereof in the inner and outer side walls 30 and 32 of the respective upright guide members 22 in a suitable manner. The hinge plate 80 includes a T-shaped flange 88 at one end thereof and a laterally extending pivot pin 92 at an opposite end thereof, with the dunnage conversion machine 10 being suitably mounted on the T-shaped flange 88, and the pivot pin 92 coupling the hinge plate 80 to one end of a gas compression spring 96 to enable relative pivotal movement between the hinge plate 80 and the gas compression spring 96. At the opposite end of the gas compression spring 96, laterally extending pivot pins 98 are provided which are suitably supported at their opposite ends by the inner and outer side walls 30 and 32 of the respective guide members 22.
The hinge plate 80, and thus the dunnage conversion machine 10 mounted thereto, is pivotable between a dunnage conversion machine operating position (FIGS. 1 and 2) and a dunnage conversion machine servicing/loading position (FIG. 6). The gas compression spring 96 dampens sudden movement of the dunnage conversion machine 10 between its operating and service/loading positions.
As shown in FIGS. 1 and 2, when the dunnage conversion machine 10 is in its operating position, the hinge plates 80 are fully retracted between the inner and outer side walls 30 and 32 of the respective upright guide members 22. When the dunnage conversion machine 10 is moved from the operating position to the servicing/loading position, and the hinge plate 80 is correspondingly pivoted about the hinge pin 82, the hinge plate 80 exerts a pulling force on the gas compression spring 96 through the pivot pin 92. Once the pulling force exceeds the resistance provided by the gas compression spring 96, the hinge plate 80 can pivot and the dunnage conversion machine 10 can pivot to the servicing/loading position.
As shown in FIG. 4, the rear wall 36 of the guide member 22 has a slot 106, the slot 106 receiving the hinge plate 80 when the dunnage conversion machine 10 is in the servicing/loading position. The perimeter of the slot 106 is reinforced by corresponding reinforcing brackets 108, the brackets 108 fitting between the inner and outer side walls 30 and 32 and being suitably attached to the inner surface of the rear wall 36. Each hinge plate 80 has an undulation or cut-out 112 so that the hinge plate 80 can pivot so that the top surface of its T-shaped flange 88 is approximately perpendicular with respect to the horizontal, as shown in fig. 6.
Each hinge plate 80 includes a plurality of laterally extending adjustment apertures 120 located on a circumference spaced a radial distance from the lateral hinge pin 82. Each adjustment aperture 120 in the respective hinge plate 80 corresponds to a position to which the dunnage conversion machine 10 can be rotated. In the exemplary embodiment shown, each hinge plate 80 has three adjustment apertures 120, with one adjustment aperture 120 corresponding to a dunnage conversion machine operating position, another adjustment aperture 120 corresponding to a dunnage conversion machine servicing/loading position, and a middle adjustment aperture 120 corresponding to a position that is midway between the dunnage conversion machine operating position and the dunnage conversion machine servicing/loading position.
A spring-actuated actuator pin 124 is provided in each upright guide member 22 (only one shown) and is spring-biased into the respective adjustment aperture 120 when the adjustment aperture 120 is brought into alignment with the actuator pin 124. The actuator pin 124 thereby secures the dunnage conversion machine 10 in the desired position. To move the dunnage conversion machine 10 to a different position, the actuator pins 124 are pulled out of their respective adjustment holes 120 and the dunnage conversion machine 10 is pivoted until the different adjustment holes 120 are aligned with the actuator pins 124, at which point the actuator pins 124 automatically snap back into the different adjustment holes 120 to secure the dunnage conversion machine 10 in its different (new) position.
As shown in FIG. 6, when the dunnage conversion machine 10 is pivoted into its servicing/loading position, the internal components of the dunnage conversion machine 10 are more accessible to an operator or user, where they might otherwise be difficult to access. In any event, the multiple locations at which the dunnage conversion machine 10 may be positioned provide multiple access points to service the machine 10. In addition, as described further below, the initial feeding of sheet stock material into the dunnage conversion machine 10 is simplified when the dunnage conversion machine is in its servicing/loading position.
Referring now to fig. 1, 7 and 8, the dunnage conversion machine 10 includes a frame 150 mounted to the stand 12, a number of conversion sub-assemblies mounted to the frame 150 for converting sheet stock material into dunnage products, a cover 154 covering each conversion sub-assembly, and an infeed paper guide assembly 158 for simplifying loading and/or splicing operations of the sheet stock material. The dunnage conversion machine 10 also includes a cover 162 at its downstream end that covers the various conversion sub-assemblies and has the various control features of the dunnage conversion machine 10 secured thereto.
The frame 150 includes a pair of upstream side walls 170 and transversely extending upstream and downstream walls 172 and 174 connected to the side walls 170 at their lateral edges. As shown in fig. 8, the upstream wall 172 is shorter in height than the downstream wall 174. The sidewalls 170 are parallel to each other and perpendicular to the upstream and downstream walls 172 and 174. The frame 150 also includes a laterally extending interior support arm 180 that extends from the bottom of the upstream wall 172 to the downstream wall 174 in an upstream-to-downstream manner to form a T-shaped configuration with the downstream wall 174. A pair of laterally spaced side arms 184 extend perpendicularly from the respective side walls 170, and a guide plate 190 is connected at its lateral edges to the respective side arms 184. The guide plate 190 is shown with holes to reduce its weight. A constant input roller 196 is rotatably mounted at its lateral ends on the distal ends of the respective side arms 184. The constant input roller 196 provides a constant input path to the conversion sub-assembly of the dunnage conversion machine 10.
The infeed paper guide assembly 158 includes a pair of side arms 200 and guide plates 204 connected at their lateral edges to the side arms 200. The guide plate 204 is shown with holes to reduce its weight. One end of the respective side arm 200 is mounted at 202 to the respective side wall 170 so as to be pivotable. The pivotal connection 202 enables the infeed paper guide assembly 158 to pivot from an open position, as shown in FIG. 7, to a closed position, as shown in FIG. 8. In the closed position, the infeed paper guide assembly 158 is positioned between the side walls 170 of the frame 150. In the open position, the infeed paper guide assembly 158 is approximately 180 ° from its closed position.
Laterally extending guide rods 210 are mounted at their ends to the respective side walls 170 and have axes coaxial with the axis of the pivotal connection 202. A gap is provided between the guide bar 210 and the guide plate 204 of the infeed paper guide assembly 158 through which the sheet stock material may pass, as shown in fig. 8.
At the opposite or distal ends of the side arms 200, guide rollers 214 are rotatably supported at their opposite ends on the respective side arms 200. An intermediate transversely extending guide bar 220 is interposed between the guide bar 210 and the guide roller 214, and is mounted at its lateral ends to the respective side walls 170 of the frame 150. The side arms 200 of the infeed paper guide assembly 158 include corresponding recessed portions 222, the recessed portions 222 being sized to receive the ends of the guide bars 220 therein when the infeed paper guide assembly 158 is in its closed position (fig. 8). FIG. 8 illustrates the path of travel 15 of the stock material as it passes through the dunnage conversion machine 10. From the stock supply 27, the sheet stock material passes between the guide rollers 202 and the plate 204. The sheet stock material then passes between the guide bar 220 and the guide plate 204 and then passes around the guide roller 214. The sheet stock material passes from the guide roller 214 alongside the guide plate 190 or below the guide plate 190 and to the constant entry roller 196. The constant input roller 196, in turn, directs the sheet stock material downstream to the conversion components of the dunnage conversion machine 10.
In accordance with the present invention, sheet stock material is substantially contained by the upright guide members 22 of the stand 12 and the dunnage conversion machine 10 so as to prevent, or at least minimize, looping or rippling of the sheet stock material that is exhibited during operation of the machine 10.
Advantageously, the path of travel 15 of the sheet stock material is substantially maintained inside the machine 10 or in close proximity to the machine 10, so that little or no paper loop is formed outside the machine 10.
Referring now to fig. 7, the infeed paper guide assembly 158 may be pivoted to an open position to provide access to the gap between the guide roller 202 and the guide plate 204. To load sheet stock material into the machine 10, the sheet stock material is initially fed beneath and through the gap by the stock supply 27. A sufficient length of sheet stock material is drawn through the gap to reach the constant entry roller 196. The infeed paper guide assembly 158 may then be swung back or pivoted about its pivotal connection 202 to its closed position whereby the sheet stock material is pushed by the guide roller 214 into the angle formed by the side arms 184 and 200 and passed around the guide roller 214. In addition, in its open position, the infeed paper guide assembly 158 provides a surface on which a new sheet stock material may be spliced to the nearly leading sheet stock material. After the splice is completed, the infeed paper guide assembly 158 need only be pivoted about its pivotal connection 202 to cause the guide roller 214 to push the sheet stock material into its path of travel 15.
Sheet stock material is fed from a constant input roller 196 to a conversion sub-assembly of the dunnage conversion machine 10. The dunnage conversion machine includes a forming section 326 and a pulling assembly 328 that are powered by a motor 330, such as a rotary electric motor. Downstream of the pulling assembly 328, a severing assembly 334 is provided for severing the continuous strip of dunnage formed by the forming section 326 into a desired length of dunnage, and a valve 336 for preventing objects from entering the downstream end of the machine 10. The forming section components, the pulling assembly 328, the severing assembly 334, and the valve 336 are mounted to the frame 150 of the dunnage conversion machine 10. The operation of the dunnage conversion machine 10 can be controlled by a known controller (not shown).
In operation of the dunnage conversion machine 10, a stock supply assembly 327 supplies sheet material to the forming section 326. The illustrated forming section 326 includes a first (upstream) pair of side guide bars 344, a second (downstream) pair of side guide bars 345, an upper guide plate 346, and a compression member 348. Side guide bars 344 and 345 are mounted to the guide plate 190 of the frame 150, and an upper guide plate 346 is mounted to the top ends of the side guide bars 344 and 345. The compression member 348 is mounted to the upstream wall 172 of the frame 150.
The upstream side guide bars 344 are spaced wider apart than the downstream side guide bars 345 so that as the sheet stock material passes through the two pairs of side guide bars 344 and 345, the side edges of the sheet stock material are folded or rolled inwardly toward each other so that the inwardly folded edges form a plurality of substantially longitudinally extending elastic crumpled portions of the sheet material to pre-form and streamline the sheet material. The side guide bars 344 and 345 cooperate with the upper guide plate 346 and the guide plate 190 to guide the sheet material to the compression member 348 (fig. 12 and 13). The compression members 348, which may also be referred to as collection members, further shape the sheet material and also serve the function of directing the shaped strip of dunnage to the pulling assembly 328. The compression member 348 may alternatively be used as the forming section 326 without the side guide bars 344 and 345. Other types of formed parts may be used, such as those disclosed in commonly owned U.S. patent application No.09/878,130, and U.S. patent nos. 5,947,886 and 5,891,009, which are incorporated herein by reference.
The pulling assembly 328 is located downstream of the forming section 326 and includes a first transfer assembly 359 and a second transfer assembly 361, the first transfer assembly 359 including a first set of transfer grippers 360 and the second transfer assembly 361 including a second set of cooperating and opposing transfer grippers 362. The transfer jigs 360 and 362 are transferred along respective circular paths.
The pulling assembly 328 performs at least one and preferably two functions when the dunnage conversion machine is operating 10. One function is a feed function whereby opposing sets of transfer grippers 360 and 362 progressively laterally engage the strip of dunnage on opposite lateral sides thereof to pull the strip of dunnage through the forming section 326 and in turn pull the sheet material from the stock supply assembly 327. The second function preferably performed by the pulling assembly 328 is a connecting function whereby the opposing sets of transfer grippers 360 and 362 deform the strip of dunnage on opposite sides thereof to form a connected strip of dunnage. Of course, other mechanisms may be used to "attach" the strip of dunnage, i.e., act on the strip of dunnage in a manner such that it will retain its void-fill and/or cushioning function as opposed to the sheet material returning to its original flat form. For example, known attachment structures include mechanisms that fold the sheet material so as to enable the sheet material to maintain its three-dimensional shape. The opposing sets of transfer grippers 360 and 362 enable the strip of dunnage to achieve a gradual lateral engagement and progressive advancement across the width of the strip to prevent, or at least reduce, the likelihood of tearing of the sheet stock material.
The pulling assembly 328 is shown in greater detail in fig. 11-13. The pair of transfer assemblies 359 and 361 define a dunnage transfer region 413 (fig. 12 and 13) therebetween, through which the strip of dunnage from the forming section 326 passes. The transfer assemblies 359 and 361 are driven by the pulling assembly drive motor 330. Transfer assembly 361 includes a drive gear 422 mounted on a shaft, and transfer assembly 359 includes a drive gear 420 mounted on a shaft that are parallel to each other and laterally spaced apart. The drive gear 422 of the transfer assembly 361 cooperates with the drive gear 420 of the transfer assembly 359 to drive the transfer assembly 359 in a direction opposite to that of the transfer assembly 361. The cooperating gears 420 and 422 are the same size and thus the speed at which the transfer assemblies 359 and 361 rotate is the same.
In the exemplary embodiment shown, the opposing sets of grippers 360 and 362 include a first set of circumferentially evenly spaced grippers 540 and 547 and an opposing second set of circumferentially evenly spaced grippers 550 and 557, respectively (FIG. 12). The clamps 540, 547 and 550, 557 are shown secured to respective hubs which are in turn mounted on respective shafts 480 and 482 for rotation therewith. The opposed sets of grippers 360 and 362 together form the above-described dunnage transfer region 413 (fig. 12 and 13) through which the strip of dunnage is progressively engaged, advanced and released laterally. The dunnage transfer region 413 extends from about the region 566 upstream of the laterally spaced axes to a region 568 downstream of the laterally spaced axes.
The clamps 540, 547 and 550, 557 of the pulling assembly 328 each have a somewhat V-shaped, or outwardly opening, bore. On opposite sides of the outwardly opening aperture are contact portions (i.e., arms forming a V-shaped opening) including arm portions (i.e., side contact portions) that are bridged by a base portion (i.e., a central contact portion). The apertures of the opposing grippers 540-. The narrowing of the gap between the clamps 540, 547 and 550, 557 eventually reaches a minimum gap dimension through which the strip of dunnage is fully laterally engaged and captured by the opposing clamps 540, 547, and 550, 557. In other words, the arm portions of the opposing grippers 540, 547 and 550, 557 are moved laterally toward each other (i.e., progressively), and the base portions of the opposing grippers 540, 547 and 550, 557 are moved laterally toward each other (i.e., progressively) to collectively grip or capture the strip of dunnage therebetween.
Once the opposing grippers 540, 547, and 550, 557 have transversely engaged the strip of dunnage, the opposing grippers 540, 547, and 550, 557 remain caught on the strip of dunnage during the time it passes through the dunnage transfer region 413. During passage through the transfer region 413, the strip of dunnage is bent and/or deformed on opposite sides thereof. At the downstream end of the pulling assembly 328, and more specifically at the downstream end of the dunnage transfer region 413, the opposing sets of grippers 360 and 362 are progressively separated from one another to release the strip of dunnage.
The quality and/or type of grippers 540, 547, 550, 557 used may vary from that shown in these figures depending on, for example, the desired circumferential spacing between the grippers, the desired point at which the strip of dunnage is engaged by the grippers (e.g., longer grippers may engage the strip of dunnage faster and/or more upstream than shorter grippers), the geometry of the grippers (e.g., the outwardly opening apertures may be semi-circular or semi-elliptical in shape to enable lateral and transverse capture operations), or the type of engagement desired by the grippers (e.g., whether it is desired to have the strip of dunnage connected by the grippers). In addition, the clamps 540-547 of one transfer assembly 359 may be longitudinally offset by a gap relative to the clamps 550-557 of the other opposing transfer assembly 361. Additionally, the pulling assembly 328 may function as a feeding assembly and/or a connecting assembly. The illustrated exemplary pulling assembly 328 both pulls sheet material (i.e., feeds sheet material) through the forming section 326 and progressively bends and/or buckles (i.e., joins) the strip of dunnage at regular intervals as it passes through the pulling assembly 328. Other attachment means may also be used, as described above.
In the illustrated pulling assembly 328, the opposing clamps are each shown with one hole. Alternatively, opposing clamps may be provided in which only one clamp includes an aperture. The gripper including the aperture collects and laterally captures the strip of dunnage therein as the opposing gripper without the aperture moves through the transfer area along with the aperture gripper. The opposing clamps may have different shapes (e.g., semi-circular or semi-elliptical) and/or sized apertures.
The continuous strip of dunnage travels downstream from the pulling assembly 328 to the severing assembly 334. The severing assembly 334 is shown in fig. 14 to 16. The severing assembly 334 severs the strip of dunnage into segments of desired length by a cutting or tearing operation. The severing assembly 334 may be of any desired type for severing the strip of dunnage. The illustrated severing assembly 334 includes a guillotine blade assembly 574 powered by a rotary motor 576 (FIG. 8) through a motion transmission assembly 578. In the illustrated embodiment, the blades of the blade assembly 574 are serrated. One revolution of the crank 580 of the motion transfer assembly 578 causes the guillotine blade assembly 574 to move from a ready to sever or open position (fig. 14 and 15) to a severed or closed position whereby the strip of dunnage is severed, and then back to the ready to sever position. The high speed rotational severing operation provided by the severing assembly 334 enables rapid, continuous severing of the strip of dunnage as it emerges from the pulling assembly 328.
Valve 336 is located downstream of shutoff assembly 334. Valve 336 is shown in fig. 16. The valve 336 includes a rectangular outlet chute 582, a door 584 pivotally mounted on and/or in the chute 582, and a position sensor (not shown). The gate 584 is spring biased or gravity biased in an inclined position wherein the gate 584 extends from an upstream end of the chute 582 (near the severing assembly 334) to a downstream end of the chute 582. When the door 584 is in its spring-biased position, the chute 582 and the inclined door 584 create a narrower opening at the downstream end of the chute 582 to prevent objects from entering therein. The door 584 can be swung open by a strip of dunnage passing through the chute 582. The severing assembly 334 is activated to sever the strip of dunnage when the position sensor detects the presence of the strip of dunnage in the chute 582. It should be understood that other valves, such as an inclined conveyor suitably coupled to the pulling assembly motor 330, may be used to prevent foreign objects from entering the discharge chute of the machine 10.
As indicated above, the conversion machine 10 may be operated by a controller. For example, the controller may cause the pulling assembly drive motor 330 to be energized when a foot pedal is depressed by the operator. The machine 10 may produce a pad whenever the pedal is depressed. When the pedal is released, the controller may cease operation of the pulling assembly drive motor 330 and begin operation of the severing assembly motor 576 to sever the strip of dunnage. Other control devices may be provided, such as those described in U.S. Pat. Nos. 5,897,478 and 5,864,484.
Referring again to fig. 8, the frame 150 provides a compact L-shaped configuration for the conversion sub-assembly. In particular, the pulling assembly motor 330 is mounted to the frame 150 such that its axis is parallel to one leg of the L-shaped structure, and the severing assembly motor 576 is mounted to the space 150 such that its axis is parallel to the other leg of the L-shaped structure.
Referring again to fig. 7-10, the conversion sub-assembly is covered by a cover 154 and a cover 162. The hood 154 is connected to the downstream wall 174 of the frame 150 by a laterally extending hinge 600. The hinge 600 enables the hood 154 to pivot between a closed position, shown in fig. 8, and an open position, shown in fig. 7, 9, and 10. The hood 154 includes an arcuate top wall 602, a pair of side walls 604 depending from side edges of the top wall 602, and an upstream wall 606 depending from an upstream edge of the top wall 602. As shown in fig. 8, the side walls 604 of the hood 154 have respective beveled edge portions that extend from the hinge 600 to the angle defined by the side walls 200 and the side arms 184. The side walls 604 of the hood 154 are laterally spaced apart a distance slightly wider than the side arms 184 and 170 of the frame 150 so that when the hood 154 is pivoted to its closed position, the side arms 184 and upper portions of the side walls 170 are contained within the side walls 604 of the hood 154. In its closed position (FIG. 8), the hood 154 protects components such as the forming section 326 and pulling assembly 328 of the dunnage conversion machine 10 from debris and foreign objects. In the open position (fig. 7, 9 and 10), these components are easily accessible and therefore can be easily assembled on the frame 150 and/or easily serviced.
The cover 162 is mounted to the downstream wall 174 of the frame 150. As shown in fig. 8, the cover 162 includes a top wall 622, the top wall 622 having an arcuate profile with the same arcuate radius as the top wall 602 of the hood 154. A pair of side walls 624 and a downstream end wall 626 depend from the top wall 622. Bottom wall 628 is connected at its side edges to respective side walls 624 and at its top edge to downstream end wall 626. As shown in fig. 1 and 8, the bottom wall 628 is substantially parallel to the bottom edge of the side wall 170 of the frame 150. The cover 162 protects components such as the severing assembly 334 and the valve 336 of the dunnage conversion machine 10 from debris and foreign objects. In addition, the cover 162 is lightweight due to its small size, and thus may be easily removed for assembly and/or servicing of the components contained within the cover 162.
The cover 162 is also ergonomically advantageous, as shown in FIG. 1, in that the cover 162 includes a control panel 640 for controlling the dunnage conversion machine 10, an emergency stop button 642 for stopping operation of the dunnage conversion machine 10, and an on-off switch 644 for turning the dunnage conversion machine on and off. An outlet aperture 650 is provided in the cover 162 through which the strip of dunnage passes from the valve 336 of the dunnage conversion machine 10. Advantageously, the downstream end wall 626 of the cover 162 faces downwardly at an angle of about 45 degrees relative to horizontal. At this angle, the cover 162 provides easy access to, and thus access to, the control panel 640, the emergency stop button 642 and the on-off switch 644 when discharging the strip of dunnage through the immediately adjacent outlet 650.
Referring now to FIGS. 17-19, three different packaging systems 700, 702, and 704 are shown that include the dunnage conversion machine 10. As shown in FIG. 17, the dunnage conversion machine 10 is mounted to a stand 710 that is in a substantially vertical orientation. The stand 710 includes a base 712 and an upright frame 714 on which the machine 10 is mounted. The machine 10 has an upstream end 716 and a downstream end 718, with sheet stock material being fed to the machine 10 at the upstream end 716 and the machine 10 discharging the dunnage pad from the downstream end 718. The support 710 has an L-shaped configuration such that when the base 712 is positioned below a work surface 730, such as a conveyor, or a table as shown in fig. 17, the downstream end 718 of the machine 10 extends above the work surface 730. Each bottom corner of base 712 includes wheels 732 to allow easy movement of support 710 and machine 10. The upright frame 714 of the stand 710 includes a pair of upright guide members between which a stack 740 of fan-folded sheet stock material is guided to the upstream end 716 of the dunnage conversion machine 10. As noted above, the sheet stock material may alternatively be provided in the form of a roll of stock material supported by the stand 710 or by a cart placed adjacent or proximate to the stand 710.
The packaging system 702 shown in fig. 18 includes a pair of packaging stations 760, wherein each packaging station 760 includes a dunnage converter 762. The dunnage conversion machine 762 is similar to the dunnage conversion machine 10 described above, except that the dunnage conversion machine 762 does not include the infeed paper guide assembly 158. The downstream end of the respective dunnage conversion machine 762 is positioned above the respective packaging surface 766. The upstream end of the respective dunnage conversion machine 762, in turn, extends upwardly toward a high loading station 768 that includes a respective stock supply assembly 770. Each feedstock supply assembly 770 is accessible from a high conduit 772.
The stock supply assembly 770 supplies sheet stock material toward the upstream end of the dunnage conversion machine 762 by way of, for example, a stock supply roll or stack of fan-folded stock material as shown. The stack of fan folded sheet stock material is guided at its lateral edges by respective laterally spaced guide posts 780 of the stock supply assembly 770. The sheet stock material is passed over upper laterally extending guide bars 790, which guide bars 790 are supported at their ends by respective upstanding guide posts 780. The sheet stock material from the guide bar 790 passes over the intermediate guide bar 792. The intermediate guide rods 792 are mounted at their ends to respective side support members 794, and the side support members 794 are mounted to and extend perpendicularly from the upright guide posts 780. In the same manner as described above with reference to the dunnage conversion machine 10, sheet stock material passes from the intermediate guide bar 792 to the constant input rollers of the dunnage conversion machine 762 and to the downstream conversion sub-assemblies of the dunnage conversion machine 762. A number of storage locations 796 for the fan-folded sheet stock material are located at a side of the aisle 772 opposite the stock supply assembly 770.
Advantageously, the packaging system 702 of the present invention separates the packaging station 760 from the loading station 768, so that the packaging and loading tasks can be performed independently. Also, the fan folded sheet stock material is stored away from the wrapping station 760.
The packaging system 704 of FIG. 19 includes a dunnage conversion machine 800 that is similar to the dunnage conversion machine 10, except that it does not include the infeed paper guide assembly 158. The dunnage conversion machine 800 is suspended from and connected to a structural member 802, such as the roof of a warehouse. More particularly, the dunnage conversion machine 800 is supported by an inverted U-shaped bracket 804. The base 806 of the U-shaped bracket 804 is mounted on the distal end of the structural member 802 and laterally spaced legs 808 of the U-shaped bracket 804 depend from the base portion 806 and are mounted on respective sides of the dunnage conversion machine 800. A pair of guides 814 and 816 of sheet stock material are located upstream of the dunnage conversion machine 800 and are mounted to the structural member 802. Each guide rail 814 and 816 provides an opening through which the sheet stock material passes before entering the dunnage conversion machine 800. Below the structural member 802, a supply of sheet stock material 820 is provided, which in the illustrated embodiment is in the form of a stack of fan-folded sheet stock material. The stack of fan folded sheet stock material 820 rests on a support 822 which includes a pair of guide posts 826 between which the sheet stock material is guided to the downstream guide rail 816. Advantageously, the dunnage conversion machine 800 is suspended away from any packaging station located therebelow and the stock supply 820 located upstream thereof.
Referring now to fig. 20 and 21, there is shown a dunnage conversion system 900 in accordance with another embodiment of the present invention, which includes a dunnage conversion machine or dunnage conversion head 910 and a stand 912. The dunnage conversion machine 910 and stand 912 are substantially identical to the dunnage conversion machine 10 and stand 12 described previously, except as described herein. Like reference numerals refer to like parts or features throughout the several views.
The stand 912 of the dunnage conversion system 900 includes a pair of upright guide members 922 on which the dunnage conversion machine 910 is mounted. Each upright guide member 922 includes an inner side wall 930, an outer side wall 932 spaced from inner side wall 930 by a gap G, a front wall 934, and a rear wall 936. Front and rear walls 934 and 936 straddle the gap G between inner and outer sidewalls 930 and 932 and extend inwardly beyond respective inner sidewall 930 to form respective front and rear guide surfaces 944 and 946. The front and rear transverse support members 948 and 950 are connected to and extend between the guide members 922 at the uppermost ends of the guide members 922. Unlike the strut 12, the strut 912 does not include a vertically extending catch 52.
Fig. 22-26 sequentially illustrate an exemplary method for loading a stack of fan-folded sheet stock material (fig. 5) between the guide members 922, as viewed from above the stack. The width of the stack is slightly less than the distance between the inner side walls 930 and slightly greater than the distance between the innermost edges of the front and rear guide walls 944 and 946. Initially, the stack is inserted laterally between the guide members 922 (fig. 22). For example, in the illustrated embodiment, the right side of the stack is inserted between the guide members 922. The stack is then tilted in a clockwise direction until diagonally opposite corners, such as the right front corner and the left rear corner in the illustrated embodiment, are located between the guide members 922, as shown in fig. 23. The right side of the stack is then moved toward the right inner side wall 930 so that the right rear corner of the stack is clear of the right rear guide wall 946 (fig. 24). The stack then continues to move toward the right inner side wall 930 a sufficient distance to enable the front left corner of the stack to exit the front left guide wall 944. The stack is then tilted in a clockwise direction until the sides of the stack are within the inner side wall 930 and the front and rear of the stack are within the front and rear guide walls 944 and 946 of the guide member 922 (fig. 25). The stack is then moved laterally to the left to approximately center the stack between the inner side walls 930 (fig. 26). Thus, the fan folded sheet stock material is captured between the inner side wall 930 and the front and rear guide walls 944 and 946. The front and rear guide walls 944 and 946 prevent or at least reduce the likelihood of the stack tipping rearwardly or forwardly out of the support 912, while the inner side walls 930 of the respective guide members 922 prevent or at least reduce the likelihood of the stack moving laterally within the support 912. This has been found to be particularly useful when the carriage is moved from one position to another on the wheels 26.
Although in the illustrated embodiment the stack is inserted between the guide members 922 by first inserting the right side of the stack, it will be appreciated that alternative methods may be used to insert the stack. For example, the left side of the stack may be inserted first, followed by tilting the stack in a counter-clockwise direction. Additionally, it should also be understood that any stack of fan folded sheet stock material may be inserted between the guide members 922 in accordance with the present invention. For example, as further described below with reference to fig. 32-39, the stack of sheet stock material may be in the form of a bale that, once inserted into the holder, may be unpacked to release it for feeding and converting by the converting machine 910.
Referring now to fig. 20, 21, and 27-31, a dunnage conversion machine or dunnage conversion head 910 is mounted to a stand 912 by a hinge 978 and a pair of mounting mechanisms 980 (hidden from view in fig. 20, 27, and 28). The hinge 978 and mounting mechanism 980 enable the dunnage conversion machine 910 to be selectively pivoted from the operating position shown in fig. 20 to the servicing/loading position shown in fig. 27 and 28. The dunnage conversion machine 910 can be pivoted toward the front of the system 910 so as to be at least partially suspended in front of the stand 912. Instead, the previously described dunnage conversion machine 10 may be pivoted toward the rear of the stand 12.
As shown in fig. 21, the hinge 978 extends laterally between the guide members 922 of the bracket 912 at its uppermost and forwardmost corners. More particularly, one end of the hinge 978 is mounted to or formed by the front cross support member 948 of the bracket 912, while the other end is mounted to a flange (not shown) that extends rearwardly from the bottom of the transverse wall 174 of the frame 150 of the dunnage conversion machine 910.
Each mounting mechanism 980 includes a mounting bracket 984, a gas compression spring 988, and a guide bracket 992. Each mounting bracket 934 has a pair of upstanding mounting posts 996 extending therefrom. The dunnage conversion machine 910 is mounted to the mounting post 996 by a pair of flanges (not shown) that project inwardly from the bottom of the side walls 170 of the conversion machine frame 150. The pivot pin 1000 couples the front end of the mounting bracket 984 to the upper end of the gas compression spring 988 to enable relative pivotal movement between the mounting bracket 984 and the gas compression spring 988. A gas compression spring 988 extends downwardly from the mounting bracket 984 and is movable between the inner and outer side walls 930 and 932 of the respective upright guide member 922. The bottom end of the gas compression spring 988 is mounted on a laterally extending pivot pin 1004 which is rotatably supported at its opposite ends by inner and outer side walls 930, 932 in a suitable manner.
A pivot pin 1008 extends from the side of the mounting bracket 984 and couples the rear end of the mounting bracket 984 to the upper end of the guide bracket 992 to enable relative pivotal movement between the mounting bracket 984 and the guide bracket 992. Like the gas compression spring 988, the guide brackets 992 extend downwardly from the mounting bracket 984 between the inner and outer side walls 930, 932 of the respective upright guide member 922. Each guide bracket 992 is arcuate in shape and includes an arcuate slot 1012 therein. As the dunnage conversion machine 910 pivots about the hinge 978 relative to the stand 912, the guide bracket 992 slides along the opposite end of the guide bar 1016 to guide this pivoting movement. The opposite ends of the guide bar 1016 are rotatably supported by respective reinforcing brackets 1020, the reinforcing brackets 1020 being sandwiched between and suitably connected to the inner and outer side walls 930, 932 of the respective upright guide member 922.
The dunnage conversion machine 910 can pivot relative to the support 912 through a wide range of angular displacements, which is defined by the distance the guide bracket 992 can travel on the guide bar 1016 when the distal end of the arcuate slot 1012 in the guide bracket 992 reaches the guide bar 1016. A control knob 1026 or similar mechanism can be suitably attached to the dunnage conversion machine 910 and/or to one or both of the mounting mechanisms 980 to lock the dunnage conversion machine 910 at a desired angular displacement relative to the stand 912, or to unlock the dunnage conversion machine 910 to enable pivotal movement of the dunnage conversion machine 910 relative to the stand 912.
In the illustrated exemplary dunnage conversion system 900, the dunnage conversion machine 910 can be selectively locked in an operating position (fig. 20) and in two different servicing/loading positions, one of which is shown in fig. 27 and 28, using the guide bar 1016 and the guide bracket 992. In particular, the guide bar 1016 is rotatably adjustable between a pivot allowing position and a pivot inhibiting or locking position. A knob 1026 (fig. 20 and 21) is accessible from the side of the bracket 912 in the illustrated embodiment, which is suitably connected to the guide bar 1016 to ensure such rotatable movement.
Referring to fig. 29, the slot 1012 of each guide bracket 992 has three arcuate recesses 1030, 1032 and 1034, each having a radius slightly larger than the radius of the guide bar 1016, and a narrower track portion 1038 extending between the recesses 1030, 1032 and 1034. The arcuate recesses 1030, 1032, and 1034 correspond to three different positions in which the dunnage conversion machine 910 may be selectively locked and unlocked, respectively. It should be appreciated that the guide bar 1016 may rotate when the central axis of the guide bar 1016 is substantially collinear with the central axis of one of the arcuate recesses 1030, 1032, 1034 of the slot 1012. The opposite end of the guide bar 1016 includes a corresponding arcuate notch 1044 therein. The axial width of each notch 1044 in the guide bar 1016 is slightly greater than the width of the guide bracket 992 to enable the radially inner arcuate portion of the guide bracket 992 to slide therein.
In the pivot allowed position (fig. 29), the guide bar 1016 is rotated so that the notch 1044 of the guide bar 1016 is aligned with the inner arcuate portion of the guide bracket 992, thereby allowing the guide bracket 992 to freely slide back and forth along the opposite end of the guide bar 1016, thus allowing the dunnage conversion machine 910 to pivot relative to the stand 912. In the pivot inhibit or locked position, the guide bar 1016 rotates such that the notch 1044 of the guide bar 1016 is out of alignment with the inner arcuate portion of the guide bracket 992 and the outer diameter of the guide bar 1016 is in the path of movement of the inner arcuate portion of the guide bracket 992 and thus prevents movement thereof. In the locked position, the guide bar 1016 prevents the dunnage conversion machine 910 from pivoting relative to the bracket 912.
When the guide bar 1016 is rotated within the recess 1030 to prevent movement of the guide bracket 992, the dunnage conversion machine 910 is in an operating position, atop the stand 912 (FIG. 20). FIG. 30 shows the gas compression spring 988 and the guide bracket 992 in their respective positions when the dunnage conversion machine 910 is in an operating position. In the operating position, the gas compression spring 988 is compressed and the weight of the dunnage conversion machine 910 is substantially carried by the compressed guide bracket 992 and by the hinge 978 at the front of the stand 912 and the top of the upright guide member 922 of the stand 912.
When the guide bar 1016 rotates within the recess 1032 to inhibit movement of the guide bracket 992, the dunnage conversion machine 910 is in the intermediate tilt service/loading position. When the guide bar 1016 rotates in the groove 1034 to block movement of the guide bracket 992, the dunnage conversion machine 910 is in the fully tilted service/loading position (fig. 27 and 28). FIG. 31 shows the gas compression spring 988 and the guide bracket 992 in their respective positions when the dunnage conversion machine 910 is in the fully tilted service/loading position. In this position, the gas compression spring 988 is extended and the weight of the dunnage conversion machine 910 is substantially carried by the tensioned guide bracket 992 and by the hinge 978 located at the front of the stand 912.
The gas compression spring 988 and guide member 992 of the mounting mechanism 980 together simplify the pivotal movement of the dunnage conversion machine 910 relative to the stand 912. For example, the gas compression spring 988 biases the dunnage conversion machine 910 so as to give the dunnage conversion machine 910 a degree of weightlessness as the dunnage conversion machine 910 pivots relative to the stand 912. At the same time, the guide bracket 992 guides the movement of the mounting bracket 984, and thus the movement of the dunnage conversion machine 910 along the guide bar 1016, as the dunnage conversion machine 910 pivots relative to the stand 912. The gas compression spring 988 and the guide bracket 992 move between the planes of the inner and outer side walls 930, 932 of the respective upright guide members 922, and, as shown in FIG. 21, the gas compression spring 988 and the guide bracket 992 are fully retracted between the inner and outer side walls 930, 932 when the dunnage conversion machine 910 is in its operating position.
Referring to fig. 20, when the dunnage conversion machine 910 is in its operating position, the dunnage conversion machine 910, and more particularly the conversion sub-assembly thereof, is positioned substantially in the plane of the side arms 184, rests above the top surfaces of the upstanding guide members 922 of the stand 912, and is inclined in the upstream-to-downstream direction at approximately 45 degrees relative to horizontal. Accordingly, the upstream end of the dunnage conversion machine 910 is remote from the packaging area surrounding the system 900, while the downstream end of the dunnage conversion machine 910, and more particularly the outlet 650 thereof, is conveniently in a direction toward the front or upstream end of the system 900 to facilitate access to the strip of dunnage discharged from the outlet 650.
Referring to FIGS. 27 and 28, access to the dunnage conversion machine 910 for servicing and/or loading thereof is simplified by tilting the dunnage conversion machine 910 forward toward one of its servicing/loading positions. In this regard, multiple service/loading locations provide multiple access points. For example, when the dunnage conversion machine 910 is in the servicing/loading position shown in FIGS. 27 and 28, the dunnage conversion machine 910 is at least partially inverted and positioned substantially below the top surface of the stand 912. The angular displacement of the side arm 184 is approximately 135 degrees from its operative position, or 180 degrees from horizontal. In this way, with the hood 154 open, an operator or user can easily access the internal components of the dunnage conversion machine 910, such as the conversion sub-assembly. Additionally, when the dunnage conversion machine 910 is in the servicing/loading position, the initial feeding of sheet stock material into the dunnage conversion machine 910 is simplified because the feed end or upstream region 566 of the pulling assembly 328 (fig. 12 and 13) is toward the front of the dunnage conversion system 900. In this way, the user or operator has substantially horizontal access to the pulling assembly 328 to feed sheet stock material into the dunnage conversion system 900 from the front thereof, and more particularly from the front of the stand 912. In addition, the operation of feeding and routing sheet stock material around the constant input roller 196 and guide roller 1064 is also simplified because substantially all of the travel path of the sheet stock material is accessible from the front of the dunnage conversion system 900.
It should be appreciated that the forward tilted dunnage conversion machine 910 can be tilted to a lower position than that achievable by the previously described backward tilted dunnage conversion machine 10. This is facilitated by the width of the cover 162 being less than the width between the upright guide members 922 of the bracket 912 such that the cover 162 can fit therebetween and the dunnage conversion machine 910 can tilt until the downstream wall 174 of the frame 150 abuts or extends parallel to the upright guide members 922.
Details of the dunnage conversion machine 910 are shown in fig. 27 and 28. The dunnage conversion machine 910 is substantially identical to the dunnage conversion machine 10 (see, e.g., FIGS. 7-16) previously described, except as described herein. Like reference numerals refer to like parts or features throughout the several views.
The dunnage conversion machine 910 includes a transversely extending feed paper guide plate 1060, the feed paper guide plate 1060 being connected at its lateral edges to the side walls 170 of the frame 150 of the dunnage conversion machine 910. The upstream end of the guide plate 1060 has a lip 1062. The guide roller 1064 is disposed at a downstream end of the guide plate 1060 and is rotatably supported at opposite ends thereof by the side wall 170. Unlike the dunnage conversion machine 10, the dunnage conversion machine 910 does not include the pivotable feed guide assembly 158 or the guide bars 202 and 220.
The path of the sheet stock material through the dunnage conversion machine is partially illustrated in fig. 27 and 28. From the stock supply 27, the sheet stock material passes through an opening in the bottom of the frame 150 and along its guide plate 1060 and lip 1062. The sheet stock material then passes around the guide roller 1064. The sheet stock material passes from the guide roller 1064 either alongside the guide plate 190 extending transversely between the side arms 184 or beneath the guide plate 190. The sheet stock material is then passed around a constant entry roller 196. The constant input roller 196, in turn, directs the sheet stock material downstream to a conversion component of the dunnage conversion machine 910 in a manner similar to that described above with reference to the dunnage conversion machine 10.
In accordance with the present invention, the sheet stock material is substantially contained by the upright guide members 922 of the bracket 912 and the dunnage conversion machine 910 so as to prevent, or at least minimize, looping or rippling of the sheet stock material that may be exhibited during operation of the machine 910. Advantageously, the travel path of the sheet stock material is substantially maintained inside the machine 910 or in close proximity to the machine 910 so that little or no paper loop is formed outside of the machine 910.
Turning now to fig. 32-38 and 40, four exemplary baled fan-folded stacks of sheet stock material 1100, 1102, 1104 and 1106 are shown in accordance with the present invention. The baled stacks 1100, 1102, 1104, and 1106 can be used in conjunction with any of the dunnage conversion machines 10 and 910 disclosed herein, or in conjunction with any suitable dunnage conversion machine or system. The baled stacks 1100, 1102, 1104, and 1106 can be easily stored and/or transported and, as described below, easily loaded into the dunnage conversion machine stands 12 and 912 on which the dunnage conversion machines 10 and 910 are mounted. Additionally, the baled stack of sheet stock material 1100, 1102, 1104, and 1106 can be easily spliced to another stack of sheet stock material.
The baled stack 1100 includes a stack 1110 of fan-folded sheet stock material, an outer sleeve 1112, and a pair of laterally spaced baling cords 1120. The stack 1110 of sheet stock material includes one or more stacks of sheet stock material fan folded into a rectangular stack. The series of folds together form a series of rectangular pages in a stacked, foldable format, stacked one on top of the other to form a stack 1110 of sheet stock material. The stack of sheet stock material 1110 has a top 1130, a bottom 1132, a front side 1134, a back side 1136, a left side 1138, and a right side 1140. For more details regarding exemplary stacks of sheet stock material and apparatus for forming the same, reference may be made to U.S. patent nos. 5,387,173 and 5,882,767, both assigned to the assignee of the present invention and incorporated herein by reference in their entirety.
The outer sleeve 1112 holds the stack of sheet stock material 1110 in a compressed form. The outer cover 1112 may be made of any suitable flexible material, such as cardboard or plastic. Outer sleeve 1112 includes a front bottom flap or tab 1150, a front panel 1152, a top panel 1154, a back panel 1156, and a back bottom flap or tab 1158, which are separated by four laterally extending fold lines 1160 (fig. 33). Fold line 1160 facilitates folding outer cover 1112 from a substantially planar, pre-folded configuration to a folded configuration shown in fig. 32-34.
The outer cover 1112 is secured to the stack of sheet stock material 1110 by a baling rope 1120. The baling rope 1120 may be made of any suitable material, such as nylon or metal wire. As shown in fig. 32, the top plate 1154 of the outer casing 1112 includes a pair of rectangular openings 1180. The bale cord 1120 extends longitudinally across the opening 1180 at approximately the center of the opening 1180. The width of the opening 1180 is slightly wider than the width of a human hand, thereby enabling the bale cord 1120 extending therethrough to be conveniently grasped through the opening 1180.
As shown in fig. 32 and 34, the outer sleeve 1112 has a width substantially the same as the width of the stack of sheet stock material 1110, and the outer sleeve 1112 does not cover the left and right sides 1138 and 1140 of the stack of sheet stock material 1110. In addition, as shown in fig. 32-34, the front and rear bottom tabs 1150 and 1158 of the outer sleeve 1112 extend below the bottom portion 1132 of the stack 1110 of sheet stock material so as to cover only a portion thereof, leaving a transverse intermediate section of the bottom portion 1132 of the stack 1110 of sheet stock material exposed.
An adhesive layer 1190, such as glue or double-sided tape, is applied to the bottom 1132 of the stack 1110 of sheet stock material. Adhesive layer 1190 is represented by dashed lines in fig. 34 and 35. The release liner 1192 is longer than the adhesive strip 1190 and covers the adhesive layer 1190. The adhesive layer 1190 and release liner 1192 are placed diagonally relative to the rectangular perimeter of the bottom 1132 of the stack of sheet stock material 1110. The adhesive layer 1900 is approximately centered on the bottom 1132 of the stack of sheet stock materials 1110. The free end of the release liner 1192 extends beyond the periphery of the bottom 1132 of the stack of sheet stock material 1110 and forms a pair of flexible pull straps 1198. When the stack of sheet stock material 1110 is secured in the outer cover 1112, the draw straps 1198 are captured between the front and back sides 1134, 1136 of the stack of sheet stock material 1110 and the respective front and back panels 1152, 1156 of the outer cover 1112.
For example, to load the packed stack 1100 into the rack 912, the packing cord 1120 is grasped through the opening 1180, and the packed stack 1100 is lifted and inserted between the upright guide members 922 of the rack 912 in the manner described above with reference to fig. 22-26, for example, such that the packed stack 1100 rests on the base 18 of the rack 912. Alternatively, the baled stack 1100 may be stacked on top of another stack of sheet stock material, for example, when it is desired to splice two stacks together. In addition, any desired number of the baled stacks 1100 may be stacked one on top of the other, the number being defined by the height available between the base 18 of the stand 912 and the dunnage conversion machine 910 thereon.
After loading the packed stack 1100 into the rack 912, the packing cord 1120 is cut and slid out from under the outer casing 1112 of the packed stack 1100. The front, rear, and/or top panels 1152, 1156, 1154 of the outer cover 1112 are then pulled upwardly and/or outwardly away from the stack of sheet stock material 1110, as shown by way of example by the arrows in fig. 33, thereby sliding and removing the front and rear bottom tabs 1150, 1158 of the outer cover 1112 from beneath the stack of sheet stock material 1110. Once the front and rear bottom tabs 1150 and 1158 have been removed from beneath the stack of sheet stock material 1110, the stack of sheet stock material 1110 drops slightly, i.e., a distance equal to the thickness of the outer sleeve 1112, onto the base 18 of the stand 912, or onto the stack if an existing stack of sheet stock material is placed on the stand 912.
The outer cover 1112 is then removed from the stent 912, thereby exposing the pull tape 1198 of the release liner 1192. In the illustrated embodiment, the outer sleeve 1112 is wider than the span between the upright guide members 922 of the bracket 912. Thus, the outer sleeve 1112 may need to be tilted or otherwise manipulated for removal from the bracket 912. It will be appreciated that the width of the outer sleeve 1112 may be smaller than the span between the upright guide members 922 of the bracket 912, in which case tilting or steering would not be required.
If a stack of sheet stock material 1110 is loaded on top of another stack of sheet stock material and it is desired to splice the upper stack 1110 to the lower stack, either of the draw belts 1198 may be pulled to remove the release liner 1192 from between the upper stack 1110 and the lower stack, thereby exposing the adhesive layer 1190 on the bottom of the upper stack 1110. The weight of the upper stack of sheet stock material 1110 presses the bottom or trailing end page of the upper stack 1110 together with the top or leading end page of the lower stack of sheet stock material. The adhesive layer 1190 pressed therebetween bonds the pages together to splice the trailing page of the sheet stock material of the upper stack 1110 to the leading page of the sheet stock material of the lower stack.
Fig. 36 and 37 illustrate another embodiment of a baled stack 1102 of fan-folded sheet stock material in accordance with the present invention. The wrapped stack 1102 is substantially identical to the wrapped stack 1100 described above, except as described herein. Like reference numerals refer to like parts or features throughout the several views.
The baled stack 1102 includes an outer sleeve having two outer sleeve members 1204 that together hold the stack of sheet stock material 1110 in its compressed form. As shown in fig. 36, the width of the outer jacket member 1204 is narrower than the width of the stack of sheet stock material 1110, and as with the previously described baled stack 1100, the outer jacket member 1204 does not cover the left and right sides 1138 and 1140 of the stack of sheet stock material 1110.
Each outer sleeve member 1204 includes a top panel 1220, a middle panel 1222, and a bottom flap or tab 1224 separated by two laterally extending fold lines 1230 and 1232. As shown in fig. 37, the intermediate panel 1222 of the outer sleeve member 1204 covers the front side 1134 and the rear side 1136 of the stack of sheet stock material 1110. The top panels 1220 extend longitudinally in opposite directions from one another to cover longitudinally spaced portions of the top 1130 of the stack of sheet stock material 1110 and are longitudinally spaced apart by a narrow transverse gap. Like the front and rear bottom tabs 1150 and 1158 of the outer sleeve 1112, the bottom tab 1224 of the outer sleeve member 1204 extends below the bottom portion 1132 of the stack 1110 of sheet stock material so as to cover only a portion thereof, leaving a transverse middle section of the bottom portion 1132 of the stack 1110 of sheet stock material exposed.
The top panel 1220 of each outer sleeve member 1204 includes a substantially oval-shaped opening 1240 sized to receive a human hand therethrough. The top panel 1220 further includes a pair of laterally spaced, longitudinally extending perforations or tear lines 1244, represented by dashed lines in FIG. 36. Tear line 1244 facilitates tearing of top panel 1220 to form a pair of handles 1248 for ease of handling of the baled stack of sheet stock material 1102, as will be described further below. The outer sleeve member 1204 is secured to the stack of sheet stock material 1110 by a baling rope 1120. The baling line 1120 is spaced laterally outward from the tear line 1244.
An adhesive layer 1190 is applied to the bottom 1132 of the stack of sheet stock material 1110 and a release liner 1192 covers the adhesive layer 1190 and also forms a pair of strips 1198. When the stack of sheet stock material 1110 is secured in the outer jacket 1204, the draw straps 1198 are captured between the front and rear sides 1134 and 1136, respectively, of the stack of sheet stock material 1110 and the intermediate panel 1222 of the outer jacket 1204.
For example, to load the packaged stack 1102 into the rack 912, the top panel 1220 is torn along tear lines 1244 to form a pair of upright handles 1248. The handle 1248 is grasped through the opening 1240 and the wrapped stack 1102 is lifted and inserted between the upstanding guide members 922 of the bracket 912 in the manner described above, for example, so that the wrapped stack 1102 rests on the base 18 of the bracket 912. Alternatively, the baled stack 1102 may be stacked on top of another stack of sheet stock material, for example, when it is desired to splice two stacks together. Once the wrapped stack 1102 is loaded into the bracket 912, the wrapping cord 1120 is cut and slid out from under the outer casing 1204 of the wrapped stack 1102. The top panel 1220 and/or the intermediate panel 1222 of each casing member 1204 is then pulled upwardly and/or outwardly away from the stack of sheet stock material 1110, as shown by way of example by the arrows in fig. 37, thereby sliding and removing the bottom tabs 1224 of the casing members 1204 from beneath the stack of sheet stock material 1110. Once the bottom tabs 1224 are removed from beneath the stack 1110 of sheet stock material, the stack 1110 of sheet stock material drops slightly, i.e., a distance equal to the thickness of the outer sleeve member 1204, onto the base 18 of the bracket 912, or onto the stack of sheet stock material located beneath the stack 1110.
The outer sleeve 1204 is then removed from the bracket 912, thereby exposing the pull tape 1198 of the release liner 1192. In the illustrated embodiment, the width of the outer sleeve 1204 is less than the span between the upright guide members 922 of the bracket 912. Thus, the outer sleeve member 1204 may be removed from the bracket 912 without the need to tilt or otherwise manipulate the outer sleeve member 1204. In an alternative embodiment, the outer sleeve 1204 may have a width that is wider than the span between the upright guide members 922 of the bracket 912, and accordingly, the outer sleeve 1204 may require such tilting operation in order to be removed from the bracket 912.
As with the previous embodiment, if it is desired to splice the upper stack 1110 to the lower stack, either of the draw belts 1198 may be pulled to remove the release liner 1192 from between the upper stack 1110 and the lower stack and expose the adhesive layer 1190. The adhesive layer 1190 pressed therebetween splices the trailing end page of the sheet stock material of the upper stack 1110 with the leading end page of the sheet stock material of the lower stack.
Fig. 38 illustrates another embodiment of a baled stack 1104 of fan-folded sheet stock material in accordance with the present invention. The baled stack 1104 is substantially identical to the baled stacks 1100 and 1102 described previously, except as described herein. Like reference numerals refer to like parts or features throughout the several views.
The baled stack 1104 includes an integral outer jacket 1260 that covers the stack of sheet stock material 1110 in a manner similar to the outer jacket 1112 of the baled stack 1100. In this regard, the outer sleeve 1260 has panels and fold lines similar to the outer sleeve 1112. The outer sleeve 1260 also has a longitudinal tear line and a top panel opening similar to the outer sleeve member 1204. The jacket 1260 additionally includes tear lines 1262 extending laterally between tear lines 1244. Together, the longitudinal tear lines 1244 and transverse tear lines 1262 facilitate tearing of the top panel 1154 to form a pair of handles 1248 for ease of manipulation of the baled stack of sheet stock material 1104.
For example, to load the baled stack 1104 into the rack 912, the top panel 1154 is torn along tear lines 1244 and 1262 to form a pair of upright handles 1248. The wrapped stack 1104 is then loaded into the holder 912 by the handle 1248 in a manner similar to that described above with reference to the wrapped stack 1102. The baling line 1120 is severed and the outer jacket 1262 is removed in substantially the same manner as the outer jacket 1112 of the baled stack 1100 is removed. The stack of sheet stock material 1110 can also be spliced to the underlying stack in substantially the same manner as described above with respect to the baled stacks 1100 and 1102.
Turning now to fig. 39, an alternative manner in which an adhesive layer 1190 and a release liner 1192 may be applied to the stack of sheet stock material 1110, or any other suitable stack of sheet stock material, in each of the baled stacks 1100, 1102, 1104, and 1106 (described below) is shown. The adhesive layer 1190 is adhered to the bottom 1132 of the stack of sheet stock material 1110 at approximately the center thereof. Unlike the orientation of the adhesive layer 1190 in the embodiment of fig. 35, which is positioned diagonally relative to the rectangular perimeter of the bottom 1132 of the stack 1110, the orientation of the adhesive layer 1190 in the embodiment of fig. 39 is such that the adhesive layer 1190 is positioned substantially parallel to the front and back edges 1134 and 1136 of the stack 1110.
The release liner 1192 covers the adhesive layer 1190 and its free end is folded over the intermediate cover portion, for example at about a right angle to the intermediate cover portion. Like the embodiment of fig. 35, the free end of the release liner 1192 extends beyond the periphery of the bottom 1132 of the stack of sheet stock material 1110 and forms a pair of flexible pull straps 1198. When the stack of sheet stock material 1110 is secured in the garment, the draw straps 1198 are captured between the front and back sides 1134 and 1136 of the stack of sheet stock material 1110 and the respective adjacent panels of the garment. The stack of sheet stock material 1110 is spliced to another stack of sheet stock material in a manner similar to the previously described embodiment of fig. 35, that is, either of the draw belts 1198 may be pulled to remove the release liner 1192 from between the upper stack 1110 and the lower stack and expose the adhesive layer 1190. The adhesive layer 1190 pressed therebetween splices the trailing end page of the sheet stock material of the upper stack 1110 with the leading end page of the sheet stock material of the lower stack.
Fig. 40 illustrates another embodiment of a baled stack 1106 of fan-folded sheet stock material in accordance with the present invention. The wrapped stack 1106 is substantially identical to the wrapped stacks 1100, 1102, and 1104 described previously, except as described herein. Like reference numerals refer to like parts or features throughout the several views.
The baled stack 1106 includes a stack 1110 of fan-folded sheet stock material, an outer wrap 1270 and a pair of laterally spaced baling cords 1120. Housing 1270 includes a base flap or tab 1274 and an upright flap or tab 1276 separated by a transversely extending fold line 1278. Base baffle 1274 and upright baffle 1276 together form an L-shaped housing 1270. In the exemplary embodiment shown, the width and length of base baffle 1274 is substantially the same as the top 1130 and bottom 1132 of the stack of sheet stock material 1110, while the width and height of upright baffle 1276 is substantially the same as the front side 1134 and back side 1136 of the stack of sheet stock material 1110. It should be understood that base baffle 1274 and upright baffle 1276 do not necessarily have to extend across the entire adjacent edge of stack of sheet stock material 1110.
The outer cover 1270 holds the stack of sheet stock material 1110 in its compressed form and secures the stack of sheet stock material 1110 by the baling string 1120. Preferably, the base baffle 1274 of the outer casing 1270 extends below the bottom 1132 of the stack of sheet stock material 1110 and the upstanding baffle 1276 is positioned adjacent to the front side 1134 or the back side 1136 as shown. Although not shown in the illustrated embodiment, corner pieces, e.g., made of plastic, may be inserted between the packing string 1120 and the stack of sheet stock material 1110 at each corner of the stack of sheet stock material 1110, e.g., at each corner of the stack of sheet stock material 1110 that is not covered by the outer cover 1270. For example, such a corner angle protects the stack of sheet stock material 1110 from any deleterious effects produced by the baling rope 1120.
An adhesive layer 1190 (not shown in fig. 40) is applied to the bottom portion 1132 of the stack 1110 of baled stacks 1106 of sheet stock material, and a release liner 1192 covers the adhesive layer 1190, as shown in fig. 35 or 39. One of the draw straps 1198 of the release liner 1192 is captured between the front side 1134 of the stack of sheet stock material 1110 and the upstanding flap 1276 of the outer cover 1270. The other draw belts 1198 remain free or may be omitted.
For example, to load the packed stack 1106 into the rack 912, the packing cord 1120 is grasped, such as by inserting a hand under the packing cord 1120, and the packed stack 1106 is lifted and inserted between the upright guide members 922 of the rack in the manner described above with reference to fig. 22-26, for example, such that the packed stack 1106 rests on the base 18 of the rack 912. Alternatively, for example, when two stacks need to be spliced together, the baled stack 1106 may be stacked on top of another stack of sheet stock material. Once the packed stack 1106 is loaded in the rack 912, the packing cord 1120 is cut and slid out from under the outer casing 1270 of the packed stack 1106. The base flap 1274 and/or upright flaps 1276 of the outer cover 1270 are then pulled upwardly and/or outwardly away from the stack of sheet stock material 1110, as shown by way of example by the arrows in fig. 40, thereby sliding and removing the base flap 1274 of the outer cover 1270 from beneath the stack of sheet stock material 1110. Once the base baffle 1274 is removed from beneath the stack of sheet stock material 1110, the stack of sheet stock material 1110 drops slightly, i.e., a distance equal to the thickness of the outer sleeve 1270, onto the base 18 of the stand 912, or onto the stack of sheet stock material beneath the stack 1110.
The outer cover 1270 is then removed from the stent 912, thereby exposing the pull tape 1198 of the release liner 1192. If it is desired to splice the upper stack 1110 to the lower stack, either of the draw tapes 1198 may be pulled to remove the release liner 1192 from between the upper stack 1110 and the lower stack and expose the adhesive layer 1190. The adhesive layer 1190 pressed therebetween splices the trailing end page of the sheet stock material of the upper stack 1110 with the leading end page of the sheet stock material of the lower stack.
It should be appreciated that various components and/or features of the baled stacks of sheet stock material 1100, 1102, 1104, and 1106 and/or the stack of sheet stock material 1110 may be combined to form alternative baled stacks of sheet stock material. For example, the outer sleeve 1112 of the baled stack 1100 of fig. 32-34 may be narrower in width than the stack of sheet stock material it covers. Additionally, the outer casing 1112 of the baled stack 1100 may alternatively comprise two separate outer casing members, such as the outer casing member shown in fig. 36. In another embodiment, the outer sleeves 1204 of the baled stack 1102 of FIGS. 36 and 37 each include an opening forming a rectangular opening similar to that shown in FIG. 32, instead of the oval opening 1240. Tear line 1244 may be spaced inward from the rectangular opening. The stack 1110 of sheet stock material in any of the baled stacks 1100, 1102, 1104, and 1106 can be provided with an adhesive layer 1190 and a release liner 1192 in the diagonal and parallel orientations described above. In an alternative embodiment, an adhesive layer 1190 and a release liner 1192 are placed on top of the stack of sheet stock material 1110. Further, the wrapped stacks 1100, 1102, 1104, and 1106 may alternatively not include such an adhesive layer 1190 and release liner 1192, such as in applications where splicing is not required. Further, the stack of sheet stock material 1110 may be partially surrounded by an outer casing without a packing cord, such as in applications where the nested stack itself may be transported and/or inserted into a rack.
Turning now to fig. 41-53, several alternative embodiments of pulling assemblies and/or forming sections suitable for use in dunnage conversion machines, such as the aforementioned dunnage conversion machines 10, 762, 800 and 910, for feeding, joining, pulling, collecting and/or crumpling sheet stock material are illustrated. It should be appreciated that the embodiment shown in fig. 41-53 may be supported and/or driven in any suitable manner or in a manner similar to that disclosed above for the pulling assembly 328 and forming section 326. Therefore, the support structure and surrounding components are not described in detail. Like reference numerals refer to like parts or features throughout the several views.
Figure 41 shows a pulling assembly 1300 and forming section 1302 in accordance with the present invention. A constant entry roller 196 is located upstream of the forming section 1302. Upstream of the constant entry roller 196 is a supply of sheet stock material, which may be in the form of a stack 1308 of fan-folded sheet stock material as shown, or in the form of a roll of sheet stock material.
The forming section 1302 includes a pair of side guide bars 345 and a compression member 1310. The compression member 1310, also referred to as a collection member, includes a tapered or funnel portion 1314 and a tube 1316 that together cause the compression member 1310 to assume a funnel shape. The illustrated tube 1316 is cylindrical in shape, but it should be understood that the tube 1316 may take other shapes, such as having an elliptical cross-section. In the exemplary embodiment shown, tapered portion 1314 and tube 1316 form a unitary structure and the downstream portion of tapered portion 1314 that transitions into tube 1316 preferably has a smooth transition radius. The compression member 1310 may be made of any suitable material, such as plastic or metal.
Pulling assembly 1300 is downstream of forming section 1302 and includes a first transfer assembly 1320 and a second transfer assembly 1330, first transfer assembly 1320 including a first set of transfer clamps 1322, and second transfer assembly 1330 including a second set of cooperating and opposing transfer clamps 1332. The clamps 1322 and 1332 are translated along respective circular paths. In the illustrated embodiment, each transfer assembly 1320 and 1330 includes four evenly circumferentially spaced clamps 1322 and 1332. The clamp 1322 of the first transfer assembly 1320 and the clamp 1332 of the second transfer assembly 1330 may rotate in or out of phase with each other (as shown). As shown, clamps 1322 and 1332 each have an outwardly opening bore that is somewhat semi-circular or semi-elliptical in shape. However, the clips 1322 and 1332 may be replaced with the clips described previously. More generally, any of the clamps described herein may be used interchangeably.
During operation of the dunnage conversion machine, sheet stock material is transferred around the constant input roller 196 and transferred between the pair of side guide bars 345. The side guide bars 345 pre-form and streamline the sheet stock material (shown in phantom between the side guide bars 345) and direct the sheet stock material to the compression members 1310 in a manner similar to that described above with reference to fig. 9 and 13. In an alternative embodiment, the side guide bar 345 may be omitted from the forming section 1302, in which case the compression member 1310 begins to guide the sheet stock material from the constant entry roller 196.
The tapered portion 1314 of the compression member 1310 and the tube 1316 further shape the sheet stock material and also perform the additional function of guiding the shaped strip of dunnage into the pulling assembly 1300. As the sheet stock material passes through the tapered portion 1314, the frictional forces exerted by the tapered portion 1314 on the sheet stock material slow the movement of certain portions of the sheet stock material while allowing other portions to more easily advance, thereby facilitating inward creasing of the sheet stock material.
Like the pulling assembly 328 described above, the pulling assembly 1300 performs at least one and preferably two functions when the dunnage conversion machine is in operation. One function is a feed function whereby opposing sets of transfer grippers 1322 and 1332 progressively laterally engage a strip of dunnage on opposite lateral sides thereof to draw the strip of dunnage through the forming section 1302 and in turn draw sheet material from a supply of sheet stock material. The second function preferably performed by the pulling assembly 1300 is a connecting function whereby the opposing sets of transfer clamps 1322 and 1332 deform the strip of dunnage on opposite sides thereof to form a connected strip of dunnage. Of course, other mechanisms may be used to attach the strip of bonding material, as described above.
It should be understood that various features of the pulling assembly 1300 and the forming section 1303 can be varied to achieve different features in the feeding and forming of the strip of dunnage. For example, in alternative embodiments, the transfer assemblies 1320 and 1330 of the pulling assembly 1300 may have fewer or more clamps 1322 or 1332 than shown, or the geometry of the clamps 1322 and 1332 may be different than shown. Additionally, the length or diameter of the tube 1316 of the forming section 1302, or the length or taper of the tapered portion 1314, may also be modified to achieve different characteristics in the feeding and forming of the strip of dunnage. Such alternatives are considered to be within the scope of the presently claimed invention.
Fig. 42 illustrates another embodiment of a forming segment 1340 according to the present invention, for example, the forming segment 1340 shown in combination with the pulling assembly 1300 of fig. 41. Shaped section 1340 is similar to shaped section 1302 described above, except that it includes a flat tapered or funnel portion 1344 that serves as both a pre-former and a former.
The shaped section 1340 includes a flat tapered portion 1344 and a tube 1348. Like tube 1316 described above, tube 1348 is shown as cylindrical in shape, but it will be appreciated that tube 1348 may take other shapes, such as having an elliptical cross-section. The flat conical portion 1344 includes a substantially triangular top wall 1350 and a bottom wall 1352, and a pair of substantially rectangular side walls 1354 and 1356, the side walls 1354 and 1356 being attached to the top and bottom walls 1350 and 1352 at their top and bottom edges and tapering inwardly toward each other in an upstream to downstream manner. At their upstream ends, the top and bottom walls 1350 and 1352, together with the side walls 1354 and 1356, form a rectangular inlet 1360, while the downstream ends transition to and are integral with the tube 1348. The wider dimension of the rectangular intake port 1360 is aligned with the plane of the sheet stock material from the constant entry roller 196 (not shown in fig. 42). If desired, the corners between the walls may be rounded, and the walls may also be rounded so that the flat tapered portion 1344 has an elliptical cross-section, such as shown in FIG. 43.
During operation of the dunnage conversion machine, sheet stock material is passed around the constant entry roller 196 and through the rectangular entry port 1360 of the forming section 1340. The flat tapered portion 1344 of the forming section 1340 pre-forms and streamlines the sheet stock material and directs the sheet stock material toward the tube 1348. The flat tapered portion 1344 and the tube 1348 together shape the sheet stock material and direct the shaped strip of dunnage into the pulling assembly 1300. As the sheet stock material passes through the flat conical portion 1344, the frictional forces exerted on the sheet stock material by the walls 1350, 1352, 1354, and 1356 of the conical portion 1344 slow the movement of some portions of the sheet stock material while allowing other portions to advance more easily, thereby facilitating inward creasing of the sheet stock material.
Fig. 44 illustrates another embodiment of a forming section 1380 in accordance with the present invention, for example, the forming section 1380 is shown in combination with the pulling assembly 1300 of fig. 41. In the fig. 44 embodiment, the forming section 1380 includes rollers 1390 and 1392 in an annular array, wherein the rollers 1390 and 1392 collectively define an aperture or mouth 1386 through which the sheet stock material passes. In the exemplary embodiment shown, there are four rollers, namely vertically spaced and substantially parallel top and bottom rollers 1390 and laterally spaced and substantially parallel side rollers 1392. Preferably, each drum 1390 and 1392 is substantially cylindrical in shape and is rotatably supported at its opposite ends by brackets 1396. For example, the brackets 1396 may be made adjustable so that the spacing between parallel rollers, such as the top and bottom rollers 1390, may be increased or decreased as needed for a particular conversion application.
During operation of the dunnage conversion machine, sheet stock material is transferred around the constant input roller 196 and through the apertures 1386 of the forming section 1380. The rollers 1390 and 1392 together form and streamline the sheet stock material to form a strip of dunnage and direct the formed strip of dunnage into the pulling assembly 1300.
In the illustrated embodiment, the rollers 1390 and 1392 are the same size and shape. It should be understood that rollers 1390 and 1392 may have different sizes and/or shapes. Additionally, although in the illustrated embodiment the top and bottom rollers 1390 are spaced the same distance apart as the laterally spaced side rollers 1392, it should be understood that the spacing may be greater or lesser, for example, depending on the particular conversion application. Additionally, although only a single aperture 1386 is shown in the illustrated embodiment, additional apertures may be formed by additional arrays of rollers, which may be longitudinally spaced from (e.g., upstream or downstream of) the first aperture 1386. In addition, the additional aperture may be shaped and sized differently than the first aperture 1386. For example, in one embodiment, the additional apertures may be smaller and positioned downstream of the first aperture 1386 such that the strip of dunnage passing through the first aperture 1386 may be further shaped and streamlined and/or reduced in cross-section as it passes through the additional apertures. Further, it should be understood that the number of rollers forming a given aperture may include three or more rollers as desired. The presently patented invention contemplates such alternatives in shape, size, number and spacing between the rollers and/or the apertures formed thereby.
Fig. 45 illustrates another embodiment of a forming section 1400 according to the present invention, for example, the forming section 1400 is shown in combination with the pulling assembly 1300 of fig. 41. The forming section 1400 is similar to the forming section 1380 previously described, except that the rolls 1412 and 1414 have concave outer surfaces and the top and bottom rolls 1412 are longitudinally spaced from the side rolls 1414. The concave shape of the rollers 1412 and 1414 facilitates rolling the sheet stock material inwardly as it passes between the rollers 1412 and 1414. Although not shown, the brackets 1420 supporting the rollers 1412 and 1414 can be made longitudinally adjustable so that the longitudinal spacing between the different sets of rollers can be increased or decreased as needed for a particular conversion application. Additionally, although in the illustrated embodiment, the forming section 1400 includes two sets of rollers 1412 and 1414, the presently claimed invention contemplates any number of sets of rollers. For example, in an alternative embodiment, the forming section 1400 may include four sets of rollers, with first and second sets of top and bottom rollers alternating with first and second sets of side rollers.
Turning now to FIG. 46, in the illustrated embodiment, there are first and second pulling assemblies 1430 and 1432 longitudinally spaced from one another. That is, the second pulling assembly 1432 is downstream from the first pulling assembly 1430. As shown, upstream of the first pulling assembly 1430 is a compression member 1440 that is configured and operates in a manner similar to the previously described compression member 348 shown in FIG. 12.
Each pulling assembly 1430 and 1432 includes a pair of transfer assemblies 1450 and 1460, and each transfer assembly 1450 and 1460 includes a set of transfer grippers 1452 and 1462. In the exemplary embodiment shown, the transfer assemblies 1450 and 1460 and their grippers 1452 and 1462 are similar in construction and function to the transfer assemblies 1320 and 1330 and their grippers 1322 and 1332 of the pulling assembly 1300 previously described.
According to the present invention, the first and second pulling assemblies 1430 and 1432 may operate at different speeds. In an exemplary embodiment, the transfer assemblies 1450 and 1460 of the second pulling assembly 1432 rotate at a slower speed than the transfer assemblies 1450 and 1460 of the first pulling assembly 1430, such that the strip of dunnage formed by the first pulling assembly 1430 crumples longitudinally between the first and second pulling assemblies 1430 and 1432. Such longitudinal wrinkles may increase the stiffness of the strip of dunnage produced by the first pulling assembly 1430.
In one embodiment of the present invention, the transfer assemblies 1450 and 1460 of each pulling assembly 1430 and 1432 may be driven independently of each other, e.g., by respective independent drive mechanisms, to achieve different speeds. Alternatively, the transfer assemblies 1450 and 1460 of each pulling assembly 1430 and 1432 may be coupled together by a speed reducer in a suitable manner to obtain different speeds. It should be understood that the transfer assemblies 1450 and 1460 and the grippers 1452 and 1462 of each transfer assembly 1450 and 1460 may have different characteristics, for example, they pull the sheet material (i.e., feed the sheet material) through the compression member 1440 and progressively bend and/or bend (i.e., connect) the strip of dunnage at regular intervals as it passes through the respective pulling assemblies 1430 and 1432. For example, the clips 1452 and 1462 of the first pulling assembly 1430 may have a different dimensional geometry or aperture than the clips 1452 and 1462 of the second pulling assembly 1432, thereby providing, for example, a connecting function. Alternatively, or in addition, the transfer assemblies 1450 and 1460 of the first pulling assembly 1430 may be laterally spaced apart from each other by a greater distance than the transfer assemblies 1450 and 1462 of the second pulling assembly 1432, to achieve, for example, different bending actions on the strip of dunnage.
Referring now to fig. 47-49, three embodiments of pulling assemblies 1470, 1472, and 1474, respectively, are shown in accordance with the present invention. The pulling assembly 1470 includes a pair of transfer assemblies 1476 that each include a set (four in the illustrated embodiment) of transfer grippers 1482. Clamp 1482 is similar to clamps 1322 and 2332 of transfer assemblies 1320 and 1330 described above, except that clamp 1482 is provided with finger tabs 1478 projecting from its inner edge.
During operation of the dunnage conversion machine, the transfer assembly 1476 collects and laterally captures the sheet stock material passing through the dunnage transfer region 1484 therebetween in a manner similar to the transfer assemblies 359 and 361, 1320 and 1330, 1450 and 1460 previously described. The projections 1478 provide a more effective gripping action on the sheet stock material, thus improving the pulling effect of the pulling assembly 1470. The projections 1478 also serve as stitching or perforating fingers that perforate the sheet stock material as it is advanced between the transfer assemblies 1476. The projections 1478 may have sharp edges for perforating the sheet stock material and may be of sufficient length to stitch together overlapping portions of the sheet stock material. This stitching helps to maintain the shape of the strip of dunnage after it is released by the transfer assembly 1476.
The pulling assembly 1472 (fig. 48) includes a pair of transfer members 1490 each having a concave outer surface and a plurality of protruding elements 1494. For example, the size, shape, number, and/or arrangement of the protruding elements 1494 will depend on the particular conversion application. In a manner similar to the previously described transfer assemblies 359 and 361, 1320 and 1330, 1450 and 1460, and 1470, the transfer members 1490 collect and laterally capture sheet stock material passing therethrough. The protruding elements 1494 frictionally engage the sheet stock material to provide a more effective gripping action on the sheet stock material, thereby improving the pulling effect of the pulling assembly 1472. The protruding elements 1494 may also function as stitching or perforating fingers that perforate the sheet stock material as it is advanced between the transfer members 1490. The protruding elements 1494 may have pointed ends for perforating the sheet stock material and may be of sufficient length to stitch together overlapping portions of the sheet stock material. This stitching helps to maintain the shape of the strip of dunnage after it is released by the transfer members 1490.
As shown in fig. 48, the pair of female transfer members 1490 define therebetween a dunnage transfer region 1496 having a substantially oval or circular cross-section. Thus, as the transfer members 1490 push the strip of dunnage through the transfer region 1496, the transfer members 1490 will transform the strip of dunnage to have a substantially cylindrical or tubular shape.
The pulling assembly 1474 (fig. 49) includes a pair of transmission members 1500, each having a cylindrical outer surface and a plurality of protruding elements 1504. The transfer member 1500 collects and laterally captures the sheet stock material passing therethrough in a manner similar to the transfer assemblies 359 and 361, 1320 and 1330, 1450 and 1460, 1470 and 1472 previously described. The projecting elements 1504 frictionally engage the sheet stock material to provide a more effective gripping action on the sheet stock material, thereby improving the pulling effect of the pulling assembly 1474. Like the protruding elements 1494 of the pulling assembly 1472, the protruding elements 1504 may also function as stitching or perforating fingers that perforate the sheet stock material as it is advanced between the transfer members 1500. The projecting elements 1504 may have pointed ends for perforating the sheet stock material and may be of sufficient length to stitch together overlapping portions of the sheet stock material. This stitching helps to maintain the shape of the strip of dunnage after it is released by the transfer member 1500.
It should be noted that the pair of cylindrical transfer members 1500 define therebetween a dunnage transfer region 1506 having a substantially rectangular cross-section. Thus, as the transfer members 1500 push the strip of dunnage through the transfer region 1506, the transfer members 1500 will convert the strip of dunnage to have a substantially narrower horizontal dimension than the vertical dimension. For example, like the aforementioned protruding elements 1494 of the pulling assembly 1472, the size, shape, number, and/or arrangement of the protruding elements 1504 will depend on the particular conversion application.
Turning now to fig. 50 and 51, another embodiment of a pulling assembly 1520 according to the present invention is shown. The pulling assembly 1520 includes a first transfer assembly 1522 and a second transfer assembly, also referred to as a clamp, in the form of a channel 1530 located opposite the first transfer assembly 1522. The illustrated delivery assembly 1522 is similar in construction and function to the delivery assemblies 1320 and 1330, and 1450 and 1460. The delivery assembly 1522 includes a plurality of clamps 1534 preferably evenly circumferentially spaced and preferably having semi-elliptical or semi-circular apertures 1536. In the exemplary embodiment shown, the transfer assembly 1522 includes four grippers 1534. The other clip or channel 1530 also has a hole 1540 (i.e., a cross-shaped cross-section) that, when viewed from the side (fig. 51), in the illustrated exemplary embodiment has substantially the same size and shape as the hole 1536 of the clip 1534. The channel 1530 preferably has a smooth surface. The transfer assembly 1522 and the channel 1530 of the pulling assembly 1520 define a dunnage transfer region 1542 therebetween having a substantially oval or circular cross-section, as shown in fig. 51.
During operation of the dunnage conversion machine, the transfer assembly 1522 and the channel 1530 opposite thereto cooperate to collect and laterally capture sheet stock material and pull it through the transfer region 1542 between the transfer assemblies 1522 and 1530 to convert the sheet stock material into a strip of dunnage. It should be appreciated that the transfer component or channel 1530 may be grooved to receive the outermost portion of the transfer component 1522 to ensure greater overlap between the transfer component 1522 and the channel 1530 and thus continuity.
Referring now to FIG. 52, one embodiment of a forming section 1550 and pulling assembly 1564 is illustrated that is similar to the forming section 1302 and pulling assembly 1300 illustrated in FIG. 41, except that the forming section 1550 does not include the pair of side guide bars 345. Another difference between the embodiments illustrated in fig. 52 and 41 is that the fan folded supply of sheet stock material 1552 in fig. 52 is smaller in width than the supply of sheet stock material 1308 in fig. 41. Similarly, the constant input roller 1556 has a width that corresponds to the forming section 1550 and is therefore smaller than the constant input roller 196 in the embodiment of fig. 41.
As the size of the sheet stock material supply 1552 and the constant entry roller 1556 is reduced, the embodiment illustrated in fig. 52 may be installed in a cushioning conversion machine having a smaller housing than the cushioning conversion machine used in the embodiment of fig. 41. The reduction in size of the buffer converter provides various advantages such as reduced transportation costs, ease of transport, more efficient servicing procedures, reduced required storage space, etc.
In the fig. 52 embodiment, the supply of sheet stock material 1552 comprises a single ply of sheet stock material that is folded upon itself, for example, in half along the length of the sheet stock material, such that the single ply of sheet stock material actually has two overlapping portions or flat plies connected at a longitudinally extending hem, such as the left in fig. 52. The longitudinally folded sheet stock material is fan folded into a rectangular stack and the series of folds together form a series of rectangular pages in a stacked, foldable pattern, stacked one on top of the other to form the stack of sheet stock material. For more details regarding exemplary stacks of longitudinally and fan folded sheet stock material and apparatus for forming the same, reference may be made to U.S. patent nos. 5,387,173, 5,882,767, 6,015,374 and 6,168,847, which are all assigned to the assignee of the present invention and are incorporated herein by reference in their entirety.
During operation of the dunnage conversion machine including the reduced width supply of sheet stock material 1552 and the constant input roller 1556, a single stack of double-ply fan-folded sheet stock material is transferred around the constant input roller 1556 and advanced to the conical or funnel portion 1558 of the forming section 1550. The forming section 1550 guides and shapes the sheet stock material and guides the formed strip of dunnage into the pulling assembly 1564.
The fig. 53 embodiment is similar to fig. 52 except that in the fig. 53 embodiment, the forming section 1570 thereof includes an expanding device 1576, the expanding device 1576 being used to expand or "expand" the single ply, two-ply, fan-folded sheet stock material prior to passing through the tapered portion 1558 to form an expanded strip of flat-folded sheet material. Thus, the flat layers are separated from each other, thereby introducing compartments into the subsequently expanded material, which now assumes a three-dimensional shape upon entering the tapered portion 1558 of the shaping segment 1550.
A method of operating any of the foregoing dunnage conversion machines 10, 762, 800 and 910 in accordance with the present invention will now be described. Any dunnage conversion machine may be adapted to include software control of ramp up speed (e.g., during startup) and ramp down speed (e.g., during shutdown), as well as different speeds at which the machine may be operating during the dunnage conversion process.
In one embodiment of the invention, the dunnage conversion machine includes controller software that is pre-programmed to operate at a particular motor start speed, three operating speeds, and a particular shut down ramp speed. In an alternative embodiment, the controller software of the dunnage conversion machine is programmed by the end user to operate the dunnage conversion machine at any desired motor start speed, at any desired operating speed, or at any desired shut down ramp speed. It should be understood that the operating speed of the motor will be determined based on the characteristics of the motor and/or other drive components of the dunnage conversion machine. This allows each end-user to program their own machine in a manner best suited for the end-user to convert applications, as different end-users may have different packaging requirements.
Although the invention has been shown and described with respect to certain preferred embodiments, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
The present invention provides one or more of the following features:
● A stand for a dunnage conversion machine, comprising: a base; a pair of upright guide members mounted on the base and supporting the dunnage conversion machine at upper ends thereof; wherein the guide members define a channel therebetween for guiding sheet stock material to the dunnage conversion machine.
● A dunnage conversion machine, comprising: a conversion sub-assembly that converts sheet stock material into a dunnage product; and a feed paper guide assembly located upstream of the converting sub-assembly; the feed paper guide assembly is movable between an open position in which a portion of the travel path of the sheet stock material is accessible, and a closed position in which the feed paper guide assembly guides the sheet stock material along the travel path.
● A dunnage conversion machine, comprising: a pulling assembly that pulls sheet stock material through the dunnage conversion machine, thereby converting the sheet stock material into a strip of dunnage, the pulling assembly being powered by a pulling assembly motor having a pulling assembly motor axis; a severing assembly that severs the strip of dunnage into a dunnage product, the severing assembly powered by a severing assembly motor having a severing assembly motor axis; a frame having an L-shaped configuration; wherein the pulling assembly motor is mounted on the frame so that its axis is parallel to one leg of the L-shaped structure and the severing assembly motor is mounted on the frame so that its axis is parallel to the other leg of the L-shaped structure.
● A packaging system, comprising: a dunnage conversion machine; and a packaging face; wherein the dunnage conversion machine is positioned above the packaging surface.
● A packaging system, comprising: a dunnage conversion machine; a stock supply assembly that supplies sheet stock material to a dunnage conversion machine; and an aisle providing access to the ingredient supply assembly.
● A packaging system, comprising: a high support member; a dunnage conversion machine mounted on the upper support member such that the dunnage conversion machine is suspended from the upper support member; and a stock supply assembly that supplies sheet stock material to the dunnage conversion machine.
● A packaging system, comprising: a support; a dunnage conversion machine having upstream and downstream ends and mounted on the stand for pivotal movement; a conversion sub-assembly that converts sheet stock material into a dunnage product; and a feed paper guide assembly located upstream of the converting sub-assembly; the feed paper guide assembly is movable between an open position in which a portion of the travel path of the sheet stock material is accessible, and a closed position in which the feed paper guide assembly guides the sheet stock material along the travel path.
● a dunnage conversion system comprising: a dunnage conversion machine; a stand for supporting a dunnage conversion machine and supporting a stack of sheet stock material located below the dunnage conversion machine, the dunnage conversion machine drawing sheet stock material from the stack of sheet stock material and converting it into a strip of dunnage product; wherein the bracket includes a pair of transversely spaced upright channel members having longitudinally extending, transversely spaced left and right inwardly facing walls and transversely extending, longitudinally spaced front and rear guide walls extending inwardly from the inwardly facing guide walls; wherein the width between the left and right sides of the stack of sheet stock material is greater than the distance between the inner edges of the guide walls but less than the distance between the inward-facing walls of the support, and the distance between the front and rear sides of the stack of sheet stock material is less than the distance between the front and rear guide walls of the support; and the stack of sheet stock material is supported between the upright channel members and the upright channel members direct the sheet stock material to the dunnage conversion machine as the dunnage conversion machine draws sheet stock material therefrom.
● a method for loading a rectangular stack of sheet stock material into a stand for a dunnage conversion machine, wherein the stand has a pair of laterally spaced upright channel members having laterally spaced left and right inwardly facing walls extending in a longitudinal direction and laterally spaced front and rear guide walls extending inwardly from the inwardly facing guide walls, and wherein a width between the left and right sides of the stack is greater than a distance between inner edges of the guide walls but less than a distance between the inwardly facing walls of the stand, and a distance between the front and rear sides of the stack is less than a distance between the front and rear guide walls of the stand, the method comprising the steps of: inserting the left or right side of the stack between the guide members; tilting the stack so that its first and second diagonally opposed corners are located between the inwardly facing walls of the brackets; moving the left or right side of the stack towards the respective left or right inner wall of the support; tilting the stack so that the left and right sides of the stack are disposed within the respective left and right walls of the support; the stack is moved laterally toward the left or right inner facing walls so as to substantially center the stack between the inner facing walls.
● a dunnage conversion system comprising: a dunnage conversion machine for converting sheet stock material into a dunnage product, the dunnage conversion machine including a pulling assembly for pulling sheet stock material into the dunnage conversion machine and an outlet through which the dunnage product is discharged; and a support; wherein the dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the outlet of the dunnage conversion machine is toward the front of the system, and one or more servicing/loading positions in which the feed end of the pulling assembly is toward the front of the system for easy access by an operator.
● a dunnage conversion system comprising: a dunnage conversion machine for converting sheet stock material into a dunnage product, the dunnage conversion machine including a severing assembly for severing a strip of dunnage into a desired length and a cover for covering the severing assembly; and a bracket including a pair of upright guide members having a width greater than that of the cover; wherein the dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the dunnage conversion machine discharges a strip of dunnage at the front of the system, and one or more servicing/loading positions in which the cover of the severing assembly is disposed between the upright guide members.
● a dunnage conversion system comprising: a dunnage conversion machine for converting sheet stock material into a dunnage product; and a support; wherein the dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the dunnage conversion machine is in an upright position and one or more servicing/loading positions in which the dunnage conversion machine is at least partially inverted.
● a baled stack of sheet stock material for use with a dunnage conversion machine, comprising: a stack of fan-folded sheet stock material; a casing for at least partially enclosing the stack; and at least one baling rope for securing the outer cover to the stack of sheet stock material.
● a nested stack of sheet stock material for use with a dunnage conversion machine, comprising: a stack of fan-folded sheet stock material; and a casing having bottom tabs located beneath the stack and movable away from each other to enable the tabs to be removed from beneath the stack.
● A stack of sheet stock material for use with a dunnage conversion machine, comprising: a stack of fan-folded sheet stock material having a top and a bottom; an adhesive layer on at least the top or bottom of the stack; and a release liner covering the adhesive layer.
● a method for loading a stack of sheet stock material onto a second stack of sheet stock material, comprising the steps of: providing first and second stacks of sheet stock material with an adhesive layer applied to the top of the first stack or the bottom of the second stack; and placing the second stack on top of the first stack, whereby the adhesive bonds the top page of the first stack to the bottom page of the second stack.
● a method for loading a stack of sheet stock material onto a second stack of sheet stock material, comprising the steps of: providing a first and second stack of sheet stock material with an adhesive layer applied to the top of the first stack or the bottom of the second stack and a release liner covering the adhesive layer; placing a second stack on top of the first stack; and pulling the release liner from between the stacked stacks of sheet stock material to expose the adhesive layer, whereby the adhesive bonds the top page of the first stack to the bottom page of the second stack.
● a baled stack of sheet stock material for use with a dunnage conversion machine, comprising: a stack of fan-folded sheet stock material; an outer sleeve having at least two baffles defining an L-shaped cross-section, a corner of the stack being positioned adjacent a corner of the L-shaped outer sleeve; and at least one baling rope for securing the outer cover to the stack of sheet stock material.
● A dunnage conversion machine for converting sheet stock material into a dunnage product, comprising: a forming assembly for forming sheet stock material into a continuous strip of dunnage; a pulling assembly downstream of the forming assembly for advancing the sheet material through the forming assembly; wherein the forming assembly includes a funnel portion through which the sheet stock material passes to form the sheet stock material into a strip of dunnage and to direct the formed strip toward the pulling assembly.
● A dunnage conversion machine for converting sheet stock material into a dunnage product, comprising: a forming assembly for forming sheet stock material into a continuous strip of dunnage; a pulling assembly downstream of the forming assembly for advancing the sheet material through the forming assembly; wherein the forming assembly includes a plurality of rollers in an endless array through which the sheet stock material passes to form the sheet stock material into a strip of dunnage and to direct the formed strip toward the pulling assembly.
● A dunnage conversion machine for converting sheet stock material into a dunnage product, comprising: first and second pulling assemblies, each pulling assembly including at least two grippers movable together relative to each other through the dunnage transfer region and cooperating to grasp the sheet stock material therebetween to advance the sheet stock material through the transfer region, and at least one of the grippers including an aperture for collecting and laterally capturing the sheet stock material therein as the gripper moves through the transfer region; wherein the first pulling assembly is located downstream of the forming assembly and the second pulling assembly is located downstream of the first pulling assembly; and wherein the first pulling assembly operates at a different speed than the second pulling assembly to longitudinally crumple the strip of dunnage passing through the dunnage transfer area.
● A dunnage conversion machine for converting sheet material into a dunnage product, comprising: a pulling assembly for advancing sheet material through the machine; the pulling assembly includes at least two opposed jaws, at least one of which is movable relative to the other jaws through the dunnage transfer region and cooperates to grasp the sheet stock material therebetween to advance the sheet stock material through the transfer region, and the moving jaws include apertures for collecting and laterally capturing the sheet stock material therein as the jaws move through the transfer region; wherein the moving jaw with the hole includes a plurality of projections projecting from an inner edge thereof to assist in gripping the sheet stock material.
● A dunnage conversion machine for converting sheet material into a dunnage product, comprising: a pulling assembly for advancing sheet material through the machine; the pulling assembly includes a pair of rotatable transfer members each having a concave outer surface and a plurality of projecting elements extending from the concave outer surface, the transfer members being opposed to each other to define a dunnage transfer region therebetween and cooperating upon rotation to collect and laterally capture sheet material therebetween and advance the sheet material through the transfer region.
● A dunnage conversion machine for converting sheet material into a dunnage product, comprising: a pulling assembly for advancing sheet material through the machine; the pulling assembly includes a pair of rotatable transfer members each having a cylindrical outer surface and a plurality of projecting elements extending from the cylindrical surface, the transfer members being opposed to each other to define a dunnage transfer region therebetween and cooperating upon rotation to collect and laterally capture sheet material therebetween and advance the sheet material through the transfer region.
● A dunnage conversion machine for converting a sheet material into a dunnage product, at least two layers of the sheet material being folded flat along their lengths and joined together along fold edges, the machine comprising: a pulling assembly for advancing the flat sheet material through the machine; expanding means for separating adjacent layers of flat-folded sheet material from one another as the flat-folded sheet material passes therethrough to form an expanded strip of sheet material; the pulling assembly includes at least two grippers movable together relative to each other through the transfer zone and cooperating to grasp the expanded strip of sheet material therebetween to advance the expanded strip of sheet material through the transfer zone, and at least one of the grippers includes an aperture for collecting and laterally capturing the expanded strip of sheet material therein as the gripper moves through the transfer zone.
● A method for converting a sheet material into a dunnage product, at least two layers of the sheet material being folded flat along their lengths and joined together along fold edges, the method comprising the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the flat-folded sheet material comprises moving the jaws together relative to each other across the transfer region to cooperatively grasp the flat-folded sheet material therebetween and advance the flat-folded sheet material through the transfer region while the apertures in at least one of the jaws collect and laterally capture the flat-folded sheet material therein as the jaws move across the transfer region.
● A dunnage conversion machine for converting sheet material into a dunnage product, comprising: a pulling assembly for advancing sheet material through the machine; the pulling assembly includes at least two grippers movable together relative to each other across the transfer area and cooperating to grasp the strip of dunnage therebetween to advance the strip of dunnage through the transfer area, and at least one of the grippers includes an aperture for collecting and laterally capturing the strip of dunnage therein as the gripper moves across the transfer area; and a software controller for controlling the speed of the pulling assembly.
● A method for converting sheet material into a dunnage product, comprising the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising ramping up the speed of the pulling assembly prior to initiating the conversion process.
● A method for converting sheet material into a dunnage product, comprising the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising ramping down the speed of the pulling assembly after completing the conversion process.
● A method for converting sheet material into a dunnage product, comprising the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising adjusting the speed of the pulling assembly to one of a plurality of preprogrammed speeds prior to using the pulling assembly to advance the sheet material through the machine.
● A method for converting sheet material into a dunnage product, comprising the steps of: using a pulling assembly to advance the sheet material through the machine; wherein advancing the sheet material comprises moving the grippers together relative to each other through the transfer region to cooperatively grasp the sheet material therebetween and advance the sheet material through the transfer region while the holes in at least one of the grippers collect and laterally capture the sheet material therein as the grippers move through the transfer region; further comprising operating the pulling assembly at a first speed; and operating the pulling assembly at a second speed.

Claims (6)

1. A dunnage conversion system includes a stand (12, 912) and a dunnage conversion machine (10, 910),
the bracket includes:
a base (18);
a pair of upright guide members (22, 922) mounted on the base (18) and supporting the dunnage conversion machine (10, 910) at an upper end thereof;
wherein the upright guide member (22, 922) defines a channel therebetween for guiding sheet stock material to the dunnage conversion machine (10, 910), and the upright guide member (22, 922) has longitudinally extending, laterally spaced left and right inwardly directed guide walls (30, 32; 930, 932) and laterally extending, longitudinally spaced front and rear guide walls (34, 36; 944, 946) extending inwardly from the inwardly directed guide walls;
wherein the dunnage conversion machine is mounted to the upright guide members.
2. The dunnage conversion system of claim 1, where a width between left and right sides of the stack of sheet stock material (27) is greater than a distance between inner edges of the front and rear guide walls (34, 36; 944, 946) but less than a distance between the inner guide walls (30, 32; 930, 932), and where the distance between the front and rear sides of the stack of sheet stock material is less than the distance between the front and rear guide walls (34, 36; 944, 946).
3. The dunnage conversion system of any of claims 1 or 2, where the stack of sheet stock material (27) is supported between upright channel members (22, 922), and the upright channel members (22, 922) guide the sheet stock material to the dunnage conversion machine (10, 910) as the dunnage conversion machine (10, 910) draws sheet stock material therefrom.
4. The dunnage conversion system of claim 1, where each bottom corner of the base has wheels that facilitate moving the stand, thereby forming a cart.
5. A dunnage conversion system as set forth in claim 1, wherein the dunnage conversion machine is pivotally mounted to the stand for movement between an operating position in which the dunnage conversion machine is in an upright position and one or more servicing/loading positions in which the dunnage conversion machine is at least partially inverted.
6. A dunnage conversion system comprising:
a dunnage conversion machine;
a stand for supporting a dunnage conversion machine and supporting a stack of sheet stock material located below the dunnage conversion machine, the dunnage conversion machine drawing sheet stock material from the stack of sheet stock material and converting it into a strip of dunnage product;
wherein the bracket includes a pair of transversely spaced upright channel members having longitudinally extending, transversely spaced left and right inwardly facing walls and transversely extending, longitudinally spaced front and rear guide walls extending inwardly from the inwardly facing guide walls;
wherein the width between the left and right sides of the stack of sheet stock material is greater than the distance between the inner edges of the guide walls but less than the distance between the inward-facing walls of the support, and the distance between the front and rear sides of the stack of sheet stock material is less than the distance between the front and rear guide walls of the support; and
wherein the stack of sheet stock material is supported between the upright channel members and the upright channel members direct the sheet stock material to the dunnage conversion machine as the dunnage conversion machine draws sheet stock material therefrom.
HK08101086.5A 2002-04-22 2008-01-28 Stand for dunnage conversion machine and dunnage conversion system HK1110272B (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US60/375,149 2002-04-22
US60/412,127 2002-09-18
US60/433,548 2002-12-13

Publications (2)

Publication Number Publication Date
HK1110272A true HK1110272A (en) 2008-07-11
HK1110272B HK1110272B (en) 2014-02-28

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