Compact dunnage converter

• US 8,419,606 B2
• Filed: 06/08/2010
• Issued: 04/16/2013
• Est. Priority Date: 06/10/2006
• Status: Active Grant

• Current Assignee: Ranpak Corp. (Ranpak Holdings Corp.)
• Original Assignee: Ranpak Corp. (Ranpak Holdings Corp.)
• Inventors: Carlson, Daniel L., Gorg, Donald A., Bilkie, Thomas A.
• Primary Examiner(s): TAWFIK, SAMEH
• Application Number:
  US12/796,112
• Publication Number:
  US 20100273624A1
• Time in Patent Office: 1,043 Days
• Field of Search: 493/464, 493/459, 493/352, 493/350, 493/407, 493/967
• US Class Current: 493/464
• CPC Class Codes: B31D 2205/0035 as fan folded web
• CPC Class Codes: B31D 2205/0047 Feeding, guiding or shaping the material
• CPC Class Codes: B31D 2205/0082 General layout of the machinery or relative arrangement of its subunits
• CPC Class Codes: B31D 5/0043 including crumpling flat material
• CPC Class Codes: B31D 5/0047 involving toothed wheels

Abstract

A compact dunnage conversion machine includes a converging chute with a restricted inlet, a powered feed assembly with a sealed gearbox, a plurality of interchangeable power supplies, and a restricted outlet chute. The converter can convert a sheet stock material into dunnage for use in packaging one or more objects in a container. The restricted inlet and outlet make it more difficult for foreign objects to enter the converter and disrupt the conversion process. The sealed gearbox interposed between the driving elements of the feed assembly and an electric motor facilitates maintenance and repair of the feed assembly, while also protecting the gears therein. Finally, the power supplies provide electrical power to the motor and can include an electrical storage device, such as a battery, or an alternating-current-to-direct-current converter which is connectable to a source of electricity for supplying that electricity to the motor in an acceptable form.

Claims

1. A dunnage converter for converting a sheet stock material into a relatively less dense dunnage product, comprising a converging chute having a first pair of opposed side walls that generally converge towards each other in a downstream direction and a second pair of opposed top and bottom walls that interconnect the side walls, the top and bottom walls defining a constriction adjacent an upstream end of the chute where the top and bottom walls gradually converge toward each other to define a minimum distance therebetween, wherein the top and bottom walls have protrusions that gradually curve toward each other at an upstream end of the converging chute to form the constriction.

2. A converter as set forth in claim 1, wherein the converter has a housing having a relatively planar bottom member that forms the bottom wall and a top member having a generally U-shape cross-section that forms the side and top walls.

3. A converter as set forth in claim 1, wherein at the constriction the side walls are spaced apart about 80 mm, and the minimum distance between the top and bottom walls is no more than about 30 mm.

4. A converter as set forth in claim 1, further comprising a powered feed assembly for feeding a stock material and an output chute downstream of the feed assembly that guides the stock material to an outlet opening thereof that is spaced from the feed assembly, the output chute having a pair of opposed walls that have a minimum distance therebetween of no more than about 32 mm adjacent the outlet opening.

5. A converter as set forth in claim 4, wherein the output chute has a length of about 150 mm to about 200 mm.

6. A converter as set forth in claim 4, wherein the outlet opening generally has a height of about 87 mm and a width of about 25 mm to about 32 mm.

7. A converter as set forth in claim 4, wherein the output chute is substantially continuous from the feed members to the outlet opening.

8. A converter as set forth in claim 1, wherein in a portion of the converging chute adjacent to and downstream from the constriction has a distance between the top and the bottom walls that is greater than the distance between the top and the bottom walls at the constriction.

9. A converter as set forth in claim 1, wherein the bottom wall of the chute has a curved surface at an upstream end that defines both the upstream end of the constriction and provides a relatively constant entry point for stock material entering the chute.

10. A converter as set forth in claim 1, wherein the top wall of the chute has a curved surface at an upstream end that extends toward the bottom wall of the chute at the constriction, and the bottom wall of the chute has a curved surface at an upstream end that extends toward the top wall of the chute at the constriction.