WO2013151659A1 - Low volume dunnage conversion system - Google Patents

Abstract

A dunnage conversion system comprises a housing having a dispensing outlet through which sheet stock material can be pulled by a user to form a strip of dunnage. The housing has a forming member with circumferentially converging side walls that gradually inwardly gather and crumple the sheet stock material as it is pulled therethrough. The system also includes a catch device operative upon movement of the dunnage strip relative thereto to catch and hold the strip for severing a dunnage product therefrom. To facilitate supplying sheet stock material in the housing, the housing has a top that is pivotably rotatable relative to a base. The pivot connection both provides for the opening action and to hold the top and the base against forces generated in withdrawing sheet stock material through an opening in the top.

Description

LOW VOLUME DUNNAGE CONVERSION SYSTEM

Related Applications

This application claims the benefit of U.S. Provisional Application No.

61/621 ,349 filed April 6, 2012, which is hereby incorporated herein by reference.

Field of the Invention

The present invention relates generally to a dunnage converting system and method for converting a sheet stock material into a dunnage product, and more particularly to such a system and method that does not require a motor.

Background

In the process of shipping one or more articles, products or other articles in a container, such as a cardboard box, from one location to another, a packer typically places some type of dunnage material in the shipping container along with the article or articles to be shipped. The dunnage material partially or completely fills the empty space or void around the one or more articles in the container to prevent or minimize any shifting of the articles in the container and/or to provide cushioning for the articles in the container during the shipping process. Some commonly used dunnage materials are plastic foam peanuts, plastic bubble pack, air bags and converted paper dunnage material.

To use storage space more efficiently, a dunnage conversion machine can be used to convert a compact supply of stock material, such as a roll or stack of paper, into a lower density dunnage material as the dunnage material is needed by the packer. These powered dunnage converters are well suited for high or medium volume applications. They also can be used for low volume applications where a small amount of dunnage is needed from time-to-time, but usually the cost is too The powered converters also are somewhat bulky and occasionally require maintenance or repair. Consequently, low volume applications have been serviced by other types of dunnage, such as plastic foam peanuts and manually crumpled newspaper. Plastic foam peanuts are messy and occupy the same volume when being stored as when being used. Crumpled newspaper also is messy and requires the packer to manually crumple the newspaper.

Another apparatus for crumpling and dispensing dunnage is shown in U.S.

Patent No. 5,131 ,903. This apparatus includes a box-like housing holding a frame. The frame has a pair of inclined side walls for guiding sheet paper from a roll of paper through a reduced dimension corrugated-shaped opening that is generally aligned with an opening in the housing. A problem with such an apparatus is that the reduced width opening is in a frame member that forms a transversely extending shelf surrounding the opening. The paper can catch on this shelf as the paper is being pulled through the opening and can potentially cause undesirable tearing of the paper. Another perceived disadvantage is that portions of the crumpled paper cannot be efficiently and effectively separated in an easy manner. Still another disadvantage is replacement of the roll of paper is a relatively involved task, requiring disassembly of the housing and inner frame. Yet another drawback is the relatively large and bulky size of the apparatus when compared to the supply of paper contained therein - that is, the apparatus contains a substantial amount of empty space within the box-like housing.

Summary

The present invention provides a dunnage system and method for low volume applications. In this system, sheet stock material is pulled from a housing by a as dunnage is needed. As the stock material is pulled from the housing, it is converted from in essence a two-dimensional sheet into a relatively less dense crumpled three-dimensional dunnage product.

This system is lightweight, compact, portable, easy to use, and is essentially maintenance free. This system has no parts that move during the conversion process; only the sheet stock material moves. More particularly, the present invention provides a dunnage system that includes a forming member having a converging side wall or walls that terminate at a reduced-size outlet through which a user can draw sheet stock material and thereby crumple the sheet stock material as it is drawn therethrough to form a relatively less dense strip of dunnage.

A method provided in accordance with the present invention includes the step of manually pulling a sheet stock material from a supply of sheet stock material and through a circumferentially converging forming member, whereby the stock material is crumpled and permanently deformed to form a relatively less dense strip of dunnagfteiother aspect of the invention provides a motor-free dunnage system that includes a supply of fan-folded sheet stock material and means for inwardly gathering and crumpling sheet stock material manually pulled therethrough.

According to another aspect of the invention, a dunnage system includes a container and a fan-fold sheet stock material contained in the container. The container has an opening in a wall of the container through which a user can draw sheet stock material and thereby crumple the sheet stock material to form a relatively less dense strip of dunnage. A forming member is mountable to the container and has a passage therethrough that can be aligned with the opening in the container. The passage in the forming member is defined by converging side walls, and additionally or alternatively the wall having the opening therein is movable between a converting position and a resupply position removed from the shipping position.

In summary, the present invention provides a dunnage conversion system that comprises a housing having a dispensing outlet through which sheet stock material can be pulled by a user to form a strip of dunnage. The housing has a forming member with circumferentially converging side walls that gradually inwardly gather crumple the sheet stock material as it is pulled therethrough. The system also includes a catch device operative upon movement of the dunnage strip relative to catch and hold the strip for severing a dunnage product therefrom. To facilitate supplying sheet stock material in the housing, the housing has a top that is pivotably rotatable relative to a base. The pivot connection both provides for the opening and to hold the top and the base against forces generated in withdrawing sheet stock material through an opening in the top.

The foregoing and other features of the invention are shown in the drawings and particularly pointed out in the claims. The following description and annexed drawings set forth in detail several illustrative embodiments of the invention; this being indicative, however, of but a few of the various ways in which the principles of the invention might be employed. Brief Description of the Drawings

FIG. 1 is a perspective view of a dunnage system in accordance with the present invention.

FIG. 2 is a side view of the dunnage system of FIG. 1 in an operating or converting configuration.

FIG. 3 is a side view of the dunnage system of FIG. 1 in a resupply position or configuration.

Detailed Description

The present invention provides a low cost dunnage system for converting a sheet stock material, such as a continuous sheet of paper, into a relatively less dense dunnage product. The sheet material is pulled through a forming member by a packer to form a strip dunnage as it is needed. As the sheet material is pulled through the forming member, it is converted from in essence a two-dimensional sheet into a relatively less dense three-dimensional crumpled dunnage product.

An exemplary dunnage system includes a housing in the form of a container a supply of sheet stock material. A converging chute is mounting to a wall of the container, which has an opening through which the sheet stock material is pulled by packer. The stock material, which is wider than the opening, is inwardly gathered, randomly crumpled and permanently deformed as it is pulled through the chute to a relatively less dense strip of dunnage. The system provides a convenient way to convert sheet stock material, such as fan-fold paper, into a relatively lower density dunnage product as it is needed.

Additionally, the housing is pivotably openable to replenish the supply of sheet stock material by moving the wall of the container having the opening therethrough from a converting position to a resupply position displaced from the converting position and generally further from the supply of stock material within the container.

An exemplary forming member is a converging chute. The chute preferably has a circumferentially converging surface. The circumferential ly converging surface defines a passage having a smaller outlet than inlet, and provides a smooth transition from the inlet to the outlet. The chute can be mounted to the container and

with the opening therein to inwardly gather and crumple the stock material as the packer pulls the stock material out of the container and through the chute.

Referring now to the drawings, and initially to FIGS. 1 -3, an exemplary dunnage system according to the invention is indicated generally by reference numeral 20. The dunnage system 20 comprises a container 22 that typically has a generally rectangular shape. The container 22 may be made of any suitable, preferably disposable or recyclable, material such as one or more of cardboard, corrugated or solid fiberboard, paperboard or plastic. The container 22 could include more or fewer walls of various orientations for storing and transporting a supply of stock nWhESTiHassembled and closed as shown in FIG. 1 , the container 22 has a movable top 24 connected to a base 26 by a hinge 28. Together the top 24 and the base 26 define an enclosed, generally rectangular volume. The top 24 has a top wall 30 with a horizontal portion 32 and an inclined portion 34 connected to the hinge 28, and three upright side walls extending from peripheral edges of the top wall 30 and connected to adjacent side walls. The top wall 30, specifically the inclined portion 34 includes an opening 36 for withdrawing sheet stock material from within the container 20. The side walls include a back wall 36 between a pair of side walls 38 and 40. The base 26 has a bottom wall 42 and at least three upright side walls extending peripheral sides of the bottom wall 42 and connected to adjacent side walls. The walls include a front wall 44 between a pair of side walls 46 and 48. The pivotable 24 is movable from a closed position shown in FIG. 1 and an open resupply position removed from the closed position, as shown in FIG. 3.

The container 22 is sized to contain a supply 50 of sheet stock material 52 therein. The supply 50 includes one or more plies of sheet stock material 52, such as paper, and more particularly kraft paper. The stock material 52 can be provided in the form of a fan-folded stack, as shown, in the form of a roll, or in the form of a stack of discrete sheets. The fan-folded stack (or stacks) can rest on the bottom wall 42 of the container 22 and substantially fill the container 22 . If discrete sheets are used, the discrete sheets preferably are interleaved and of sufficient length such that pulling a leading sheet off the stack will draw a trailing sheet with it, one after the other. If one or more stock rolls are used, the stock roll or rolls can be supported in the container by suitable means for rotation so that the stock material can be paid off from the outside of the roll. In an alternative arrangement, the stock roll or rolls can be supported on one or more outer portions of the roll so that stock material can be withdrawn from the center or inside of the roll. Regardless of the type of stock supply, preferably the stock material 52 is perforated or otherwise weakened along longitudinally-spaced, transversely-extending tear lines to enable and/or facilitate separating discrete sections of dunnage from the dunnage strip formed as the stock material is pulled from the container 22.

The opening 36 in the container 22 has a width dimension less than the width of the sheet stock material whereby the stock material will be gathered inwardly and crumpled as the sheet stock material is drawn from the stock material supply 50.

A forming member 54 is mounted to the top wall 30, aligned with the opening

To this end, the forming member 54 may have a peripheral mounting flange affixed to the top wall 30 (or other wall containing the opening). Preferably the mounting flange is attached by an adhesive to the inside surface of the top wall generally centrally disposed in the top wall of the container. The transition between the mounting flange and the larger end of the converging portion of the forming member can be rounded a smooth transition that reduces or avoids catching of the paper thereon. As will be appreciated, the forming member 54 can be stored in the container 22 between the wall 30 and the supply 50 of stock material 52 when the dunnage system 20 is in its closed configuration. When the container 22 is opened for the first time, the forming member 54 can be positioned adjacent to and may protrude through the opening 36. To facilitate such attachment, the forming member 54 may have on its mounting double-sided tape or other adhesive, and a release layer covering the adhesive. The release layer can be removed to expose the adhesive so that the mounting flange be mounted to the top wall as described.

A dispensing outlet 56 thus is formed by the forming member 54 when it is mounted to align with or extend through the opening 36 in the top wall 30 of the container 22. The forming member 54 is made of a relatively rigid material that preferably has a smooth interior surface over which the sheet stock material can flow relatively freely. The forming member 54 may be in the form of a funnel or chute as shown. The chute 54 may have a rounded cross-sectional shape, such as a circular or elliptical shape, although other shapes also could be effective for gathering and crumpling the stock material as it is pulled through the chute. This forming member 54 guides and shapes the stock material in a circumferentially converging manner to inwardly gather and randomly crumple the stock material as it is drawn therethrough. The illustrated forming member 54 has a converging side wall or walls that define a passage therethrough and terminate in a reduced-width outlet opening 56 spaced from a wider inlet opening located at the opening 36 in the wall. Thus the forming member 54 functions as a funnel or converging chute and generally provides a gradual and relatively smooth transition from a relatively larger inlet opening to a relatively smaller outlet opening 56. Those skilled in the art will also appreciate that other forming members could be used.

In the illustrated embodiment, the converging chute 54 terminates at a dispensing outlet catch device 60 that facilitates separating one or more sections of dunnage from the crumpled strip for filling a void around one or more objects in a container.

This catch device 60 includes an axially-aligned segmented extension of the chute through which the stock material can pass without interference. The wall defining the dispensing outlet 56 can be formed of a metal material such as steel, or the outlet opening 56 can be lined with a metal such as steel, as metal and

steel has been found to have an advantageous gripping capability with kraft paper, the illustrated embodiment the catch device 60 includes two segments 62 and 64, between which the stock material is readily pulled. Each segment 62 and 64 tapers a downstream direction, forming longitudinally-extending notches 66 between segments. The notches 66 generally narrow in an upstream direction, and can be cut from or otherwise formed adjacent the downstream end of the chute to form the catch device 60. The catch device 60 typically is rotatable relative to the converging chute 54.

For use and/or storage, the dunnage system 20 will be in the closed

configuration shown in FIG. 1 . Because the preferred container 22 is substantially rectangular, multiple containers can be compactly stacked one atop the other and closely adjacent one another.

This dunnage system 20 is expected to be used in low-volume situations, but when the supply 40 of sheet stock material 42 finally is exhausted, the system 20 provides an easy way to open the container 22 to resupply the stock material 42.

When the dunnage supply 50 needs to be replaced, the container 22 is by pivotably moving or rotating the top wall 30 of the container 22 (or other wall containing the outlet opening 36) thereby to displace the dispensing outlet 56 and/or forming member 54 further from the supply 50 of sheet stock material 52 contained in the container 22. The hinge 28 permits the top 24 to rotate relative to the base 26, thereby providing access to the interior of the base 26 and the supply 50 of sheet material 52. To open the container, the front wall, which may be hinged at its front edge to the front wall, may be rotated forward through an angle of approximately 45- 45-120 degrees, and more preferably about 96 degrees. The stock material 52 typically is resupplied before the old supply is depleted, so that a new supply of stock material can be spliced to the old supply, thereby permitting uninterrupted feeding of the stock material 52 from the container 22 and through the forming member 54. The hinge 28 also holds the front of the top 24, specifically the inclined portion 34, to the front wall 44 of the base 26. Thus, as stock material 52 is withdrawn through the forming member 54 mounted to the inclined portion 34, the top 24 generally remains its closed position shown in FIG. 1 . A catch or other feature that limits the extent to which the top 24 can move relative to the base can be provided to limit the extent to which the top 24 can move relative to the base 26 as the sheet stock material 52 is pulled through the forming member 54.

When the container 22 is open, as shown in FIG. 3, the opening 36 in the top wall 30 of the container 22 can be easily accessed for mounting, repair, or removal of the forming member 54. To start the conversion process, a leading end of the sheet stock material 52 can be fed through the forming member 54 and out the dispensing outlet 56. The top 24 can then be returned to its closed position and stock material withdrawn from the dispensing outlet 56, thereby inwardly gathering and crumpling stock material for use as dunnage. If desired, a bottom surface of the base 26, specifically the bottom wall 42, may be provided with adhesive that can be used to the container 22 to a surface so that it doesn't move as the stock material is particularly as the stock supply 50 nears its end.

With the container 22 closed and loaded with a supply 50 of sheet stock 52, the dunnage system 20 is ready for use. A packer can grab the crumpled dunnage strip protruding from the dispensing outlet 56 and pull the strip from the container 22. As this is done, the sheet stock material 52 will be pulled from the supply 50 thereof and through the forming member 54 and dispensing outlet 56, whereby the sheet stock material will be gathered and circumferentially progressively crumpled to form the dunnage strip that is being pulled from the container 22 by the packer. When a desired amount of dunnage has been pulled from the container 22, the packer can tear, cut or otherwise separate a section of the dunnage strip for use packing one or more articles in a shipping carton or the like.

More specifically, the operator pulls the sheet stock material from the dispensing outlet 56 and past the catch device 60. The catch device 60 has an axial passage therethrough that has substantially the same cross-section as the

dispensing outlet 56 of the converging chute 54, and therefore adds little or no resistance to the stock material passing therethrough. When the operator has withdrawn the desired amount of dunnage, the operator can move the strip of dunnage into one of the notches 66 in the catch device 60, which grips the strip and facilitates tearing the stock material at or downstream of the catch device 60. The catch device 60 optionally can be rotatable to position the notches 66 at a convenient orientation preferred by the operator. Thus, after an operator, e.g. a packer or other user, pulls a desired length of dunnage from the container 22, the operator can jerk the strip sideways relative to the axis of the passage, whereupon the strip will move into one of the notches 66. As the strip is forced into the notch 66, it will be gripped by the notch 66 and thus held against further withdrawal from the container. If the strip is provided with longitudinally-spaced, transversely extending weakened regions, such as a transverse rows of perforations, as is preferred, the strip can be torn along a row of perforations located at or downstream of the catch device 60.

If the stock material is not perforated or otherwise weakened, the catch device

60 can still assist in severing the strip, such as by holding the strip to facilitate cutting of the strip with a knife. Alternatively, the device 60 can have associated therewith a knife edge for cutting the strip when the strip is moved against the knife edges. To this end, the device 60 can include a cutting blade forming one or more knife edges at the sides of the opening and particularly the sides of the notches 66. The knife edge can be straight, curved, serrated or have another shape. Another example of a catch device includes a serrated edge at a side thereof, where the tips of the serrations can bite into the stock material to hold it in place while is it is pulled across the side cutting edges of the serrations for severing a dunnage product from the strip. In summary, the present invention provides a dunnage system that does not require a motor to feed the stock material, to affect the shape of the crumpled dunnage product or to sever discrete dunnage products. A motor requires a source of power, fuel or electricity, for example, and such power sources might not be conveniently available at the location where the converter is being used. Moreover, without a motor, the system generally will be lighter weight. The lighter weight in turn makes the system more portable and easier to move to different locations. Finally, the very simplicity of the system and its lack of many moving parts generally makes it easier and less expensive to build, maintain and operate.

Although the invention has been shown and described with respect to a embodiment, equivalent alterations and modifications will occur to others skilled in art upon reading and understanding 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 that performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure that performs the function in the herein exemplary embodiment of the invention.

Claims

What is claimed is:

1 . A dunnage system for converting sheet stock material into a relatively less dense dunnage product, comprising a forming member having a converging side wall or walls that terminate at a reduced-size outlet through which a user can draw sheet stock material and thereby crumple the sheet stock material as it is drawn therethrough to form a relatively less dense strip of dunnage.

2. A system as set forth in claim 1 or any other claim, comprising a container for a supply of stock material.

3. A system as set forth in claim 1 or any other claim, wherein the forming member is defined by a housing having a passage therethrough, the passage being defined by circumferentially converging side walls terminating at a reduced-size outlet that constrains the stock material drawn therethrough.

4. A system as set forth in claim 1 or any other claim, comprising a replaceable supply of sheet stock material supported by the container, the supply of sheet stock material including at least one of a roll of sheet stock material and a stack of fan-folded sheet stock material.

5. A system as set forth in claim 1 or any other claim, comprising a catch device downstream of the forming member for catching the strip of dunnage so that a section of dunnage can be separated from the strip.

6. A dunnage system for converting sheet stock material into a relatively less dense dunnage product, comprising a housing in the form of a container and a fan-folded sheet stock material contained in the container, the container having an opening in a wall of the container through which a user can draw sheet stock material for crumpling of the sheet stock material into a relatively less dense strip of dunnage.

7. A system as set forth in claim 6 or any other claim, comprising a forming member that is attached or attachable to the container, the forming member having a passage therethrough that can be aligned with the opening in the container.

8. A system as set forth in claim 7 or any other claim, wherein the passage in the forming member is defined by converging side walls.

9. A system as set forth in claim 8 or any other claim, wherein the forming member is a converging chute that has a mounting flange that extends generally perpendicular to an axis of the passage through the chute, the mounting flange being attached to or configured for attachment to the container.

10. A system as set forth in claim 6 or any other claim, wherein the wall having the opening therein is movable between a converting position and a resupply position rotatably displaced from the converting position.

1 1 . A system as set forth in claim 6 or any other claim, wherein the dispensing opening is formed in a top wall of the container that is hingedly connected to a side wall of the container.

12. A motor-free dunnage system for converting sheet stock material into a relatively less dense dunnage product, comprising a dispensing outlet through which a relatively less dense strip of dunnage can be pulled by a user, and a catch device downstream of the dispensing outlet for catching the strip of dunnage so that a section of dunnage can be separated from the strip.

13. A system as set forth in claim 12 or any other claim, wherein the catch device is operative upon movement of the strip of dunnage relative thereto to hold the stock material for severing a section of dunnage from the strip.

14. A system as set forth in claim 13 or any other claim, wherein the catch device is operative upon sideways movement transverse the axis of the forming member to catch and hold the strip of dunnage.

15. A system as set forth in claim 12 or any other claim, wherein the catch device includes at least one notch with a decreasing width.

16. A system as set forth in claim 12 or any other claim, wherein the catch device includes a knife edge for severing a section of dunnage from the strip.

17. A system as set forth in claim 12 or any other claim, wherein the forming member includes a circumferentially converging chute.

18. A system as set forth in claim 12 or any other claim, comprising a replaceable supply of sheet stock material upstream of the forming member that includes at least one of a fan-folded stack or a roll of sheet stock material.