[0001] Apparatus for Producing Dunnage

CROSS REFERENCE TO RELATED APPLICATION

[0002] This application is entitled to priority pursuant to 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/174,916, entitled "Apparatus for Producing Dunnage," filed June 12, 2015, the disclosure of which is incorporated by reference in it entirety herein.

BACKGROUND OF THE INVENTION

[0003] The present invention is generally directed to an apparatus for producing dunnage, void fill and protective packaging.

[0004] Conventional dunnage producing machines include a plurality of moving components, such as gears and drivetrains, which are subjected to a strenuous amount of wear and tear without adequate lubrication. Consequently, dunnage producing machine internal components generally exhibit poor longevity. Further, maintenance, repair or replacement of these internal components is challenging and time consuming because many of the components are not readily individually disassembleable from the remainder of the other components. Therefore, maintenance or repair of the machines is generally expensive and requires considerable downtime, resulting in disruption of dunnage production efficiency, and ultimately, dunnage production output.

[0005] Therefore, it would be advantageous to manufacture an apparatus for producing dunnage, void fill or protective packaging comprising primarily of modular internal components exhibiting increased longevity and that are more readily accessible when repair or maintenance is required.

BRIEF SUMMARY OF THE INVENTION

[0006] Briefly stated, one aspect of the present invention is directed to an apparatus for producing dunnage from a rope of material. The apparatus comprises a rotatably mounted main transmission drive shaft to rotate about a central axis thereof. The main drive shaft has an entry aperture, an opposite exit aperture and a hollow channel extending therethrough from the entry aperture to the exit aperture for feeding of the rope of material therethrough and twisting of the rope with rotation of the main drive shaft. A motor is operatively connected to the main drive shaft for rotation thereof. A non-rotating sun gear having a central axis aligned with the central axis of the main drive shaft is positioned proximate the entry aperture. A plate is fixedly mounted to the main drive shaft for rotation therewith and has a first planetary gear pinion rotatably mounted to a first end thereof and a second planetary gear pinion rotatably mounted to an opposing second end thereof, such that the plate and the first and second planetary gear pinions rotate with the main drive shaft about the central axis thereof. The first and second planetary gear pinions are also drivingly coupled with the non-rotating sun gear, such that rotation of the plate and the first and second gear pinions about the central axis of the main drive shaft effectuates individual spinning of the first and second gear pinions about respective central axes thereof. First and second opposing bevel gear sets are fixedly and respectively attached to the first and second ends of the plate for rotation therewith, each bevel gear set including a first shaft extending in a direction generally parallel to the main drive shaft and a second shaft extending in a direction generally perpendicular to the main drive shaft. The first shaft of the first bevel gear set is fixedly attached to the first planetary gear pinion for spinning therewith and the first shaft of the second bevel gear set is fixedly attached to the second planetary gear pinion for spinning therewith, which, in turn, is translated via the bevel gear sets into spinning of the corresponding second shafts thereof about respective central axes of the second shafts. A first feed wheel is fixedly attached to a free end of the second shaft of the first bevel gear set for spinning therewith, and a second feed wheel is fixedly attached to a free end of the second shaft of the second bevel gear set for spinning therewith. The feed wheels are located on opposing sides of the main drive shaft and the main drive shaft includes two corresponding apertures on opposing sides thereof, each aperture extending into the channel and each aperture receiving a portion of a respective feed wheel therein, such that the first and second feed wheels face one another within the channel. The feed wheels are distanced apart to grab and feed the rope of material, via the spinning thereof, through the channel toward the exit aperture.

[0007] Another aspect of the present invention is directed to an apparatus for producing dunnage from a rope of material. The apparatus comprises an infeed system including an extension member. The extension member has a plurality of adjustably spaced apart bearing assemblies positioned in series for advancing the material therethrough. An assembly is located downstream of the infeed system and rotatably mounted relative to the extension member to twist the material into the rope. The assembly includes feed wheels positioned to grab the rope of material from the infeed system, crumple the rope of material and feed the rope of material through the assembly. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0008] The following detailed description of a preferred embodiment of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings an embodiment which is presently preferred. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0009] Fig. 1 is perspective view of an apparatus for producing dunnage according to a preferred embodiment of the invention;

[0010] Fig. 2 is a top perspective view of an infeed unit of the apparatus for producing dunnage of Fig. 1 ;

[0011] Fig. 3 is a front perspective view of the internal components of the dunnage producing machine of the apparatus of Fig. 1 , attached to a back plate of the machine;

[0012] Fig. 4 is an exploded perspective view of the main transmission drive shaft of the dunnage producing machine of the apparatus of Fig. 1;

[0013] Fig. 5 is a sectional view of the internal components of the dunnage producing machine of the apparatus of Fig. 1, taken along sectional line 5-5 of Fig. 1; and

[0014] Fig. 6 is a top elevational view of the dunnage producing machine of the apparatus of Fig. 1, with a top cover of the housing of the machine removed.

DETAILED DESCRIPTION OF THE INVENTION

[0015] Certain terminology is used in the following description for convenience only and is not limiting. The words "lower," "bottom," "upper" and "top" designate directions in the drawings to which reference is made. The words "inwardly," "outwardly," "upwardly" and "downwardly" refer to directions toward and away from, respectively, the geometric center of the machine, and designated parts thereof, in accordance with the present disclosure. Unless specifically set forth herein, the terms "a," "an" and "the" are not limited to one element, but instead should be read as meaning "at least one." The terminology includes the words noted above, derivatives thereof and words of similar import.

[0016] It should also be understood that the terms "about," "approximately," "generally," "substantially" and like terms, used herein when referring to a dimension or characteristic of a component of the invention, indicate that the described dimension/characteristic is not a strict boundary or parameter and does not exclude minor variations therefrom that are functionally the same or similar. At a minimum, such references that include a numerical parameter would include variations that, using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.), would not vary the least significant digit.

[0017] Referring to the drawings in detail, wherein like numerals indicate like elements throughout, there is shown in Figs. 1-6 an apparatus for producing dunnage generally designated 10, in accordance with a preferred embodiment of the present invention. As should be understood by those of ordinary skill in the art, dunnage is a formed piece particularly for use as packing material, produced from a cellulose-based sheet material, such as paper, e.g., recycled or waste paper. As also should be understood by those of ordinary skill in the art, the apparatus 10 may alternatively or additionally produce void fill, protective packaging and the like.

[0018] As shown in Fig. 1, the apparatus 10 includes an infeed system 12 and a dunnage producing machine 14. Referring to Fig. 2, the infeed system 12 comprises an inverted cone or funnel 16 and an extension member 20, connected by an elbow tube 18 therebetween. The elbow tube 18 is connected to a first bearing assembly 20d at a first end of the extension member 20, e.g., a roller bearing assembly, having a hole (not shown) with a first diameter. The extension member 20 includes a second roller bearing assembly 20a having a hole 20a' with a second diameter, followed by a third roller bearing assembly 20b having a hole 20b' with a third diameter, and an exit aperture 20c of a fourth diameter proximate an end of the extension member 20 connecting to a back plate 22a of the machine 14 (as will be described further below). The first, second, third and fourth diameters define progressively narrower inner channels in a direction approaching the back plate 22a of the machine 14. The inverted cone 16 is configured to receive paper pulled from the center of a roll S, e.g., a 35" diameter by 14" high cordless paper roll, which travels up the cone 16, through the elbow tube 18 and advances through the extension member 20, where the first, second and third roller bearing assemblies 20d, 20a, 20b permit the paper to twist into a rope R. The diameter of the rope R progressively decreases between the first roller bearing assembly 20d to the exit aperture 20c (in order to pass through the progressively narrower respective inner channels thereof), and is thereafter fed into the machine 14 through the back plate 22a thereof.

[0019] The respective diameter of at least the holes of the first, second and third bearing assemblies are adjustable, in order to achieve the desired density, i.e., tightness, of the rope R. Further, the position of the second and third bearing assemblies 20a, 20b within the extension member 20 is slidably adjustable, thereby adjusting the spacing between the bearing assemblies 20d, 20a, 20b and between the third bearing assembly 20b and the exit aperture 20c to also assist in achieving the desired shape and density of the rope R. For example, at least one guide rod 21 (four parallel guide rods 21 in the illustrated embodiment of Fig. 2) extends axially through the extension member 20 and through the second and third bearing assemblies 20a, 20b. The second and third bearing assemblies 20a, 20b are therefore slidable along the guide rod(s) 21 to adjust the position thereof. The second and third bearing assemblies 20a, 20b are then securable to the extension member 20 at the desired position. For example, without limitation, the second and third bearing assemblies 20a, 20b may be pinch clamped into place, i.e., at least one fastening/locking screw 23 threaded through the second and third bearing assemblies 20a, 20b, respectively, and engaged with the extension member 20 in a manner well understood by those of ordinary skill in the art. As also should be understood by those of ordinary skill in the art, the second and third bearing assemblies 20a, 20b may be slidable through the extension member 20 and securable thereto via any of numerous alternative methods currently known, or that later become known.

[0020] Referring to Figs. 3-6, the machine 14 comprises a housing 22 (Fig. 1), generally in the form of a parallelepiped, enclosing the internal, modular, i.e., individually disassembleable and replaceable, components of the machine 14 therein. Different portions of the housing 22 are removed from the respective Figs., to show the internal, modular components of the machine 14. The machine 14 includes a main transmission drive shaft 24 through which the rope R advances from the back plate 22a of the housing 22 to a front plate 22b of the housing 22. In the illustrated embodiment the shaft 24 includes a front shaft portion 24a (rotatably attached to the front plate 22b), a middle shaft portion 24b, a rear shaft portion 24c (rotatably attached to the back plate 22a) and a channel 24d extending through the main drive shaft 24.

[0021] As should be understood by those of ordinary skill in the art, the main drive shaft 24 is rotatably attached at opposing ends to the front and back plates 22b, 22a of the housing 22 via any of numerous different means currently known, or that later become known, allowing the main drive shaft 24 to rotate about a central axis thereof (as discussed further below), with respect to the stationary housing 22, in a friction reducing manner. For example, without limitation, the main drive shaft 24 may be connected to the housing 22 via ball bearing assemblies at the front and rear ends of the main drive shaft 24. In the illustrated embodiment, each of the front and rear shaft portions 24a, 24c includes a plurality of rings attached in series and progressively decreasing in diameter. The middle shaft portion 24b defines an outer rectangular shape. However, as should be understood by those of ordinary skill in the art, the main drive shaft 24 is not limited to the current geometry and may take the form of other shapes capable of performing the functions of the main drive shaft 24 as described herein.

[0022] As shown best in Figs. 4-5, the shaft 24 is rotatable about the central axis A thereof by an electric drive motor 26, e.g., a 3400 to a 3600 rpm motor, mounted inside the housing 22. As should be understood, the motor 26 includes a rotating driving pulley 28 fixedly mounted to a drive shaft 28a thereof and the shaft 24 includes a driven pulley 30 mounted, e.g., keyed, to the front shaft portion 24a. The driving pulley 28 and the driven pulley 30 are linked together by a timing belt (not shown) extending around both pulleys 28, 30. Accordingly, rotation of the driving pulley 28 (via the motor) drives rotation of the driven pulley 30 about the central axis A, thereby rotating the entire shaft 24 about the central axis A. The diameter of the driven pulley 30 is sized greater than the diameter of the driving pulley 28 such that the shaft 24 is rotated about the central axis A thereof at approximately 1000 to 1400 rpm. However, as should be understood by those of ordinary skill in the art, the drive motor 26 may be more of less powerful and/or the driven pulley 30 may alternatively have a larger or smaller diameter to induce lower or higher rpm.

[0023] As generally explained above, the rear shaft portion 24c is rotatably secured to the back plate 22a and the front shaft portion 24a is rotatably secured to the front plate 22b. As shown in Fig. 5, the back plate 22a includes a toothed, stationary, i.e., non-rotating, sun gear 36 secured thereto, surrounding an aperture 37 in the black plate 22a. The rear shaft portion 24c projects through the stationary sun gear 36 to the aperture 37 of the back plate 22a and communicates with the extension member 20 of the infeed system 12 at the aperture 37. Thus, the main drive shaft 24 and the stationary sun gear 36 define the same central axis A.

[0024] A plate 38 (Figs. 3-5) is keyed to the rear shaft portion 24c, and is therefore rotatable about the central axis A along with the main drive shaft 24. Two planetary, toothed gear pinions 40 are rotatably mounted to opposing ends of a rear side 38a of the plate 38. That is, as explained further below, the gear pinions 40 may rotate about the central axis A, along with main drive shaft 24 and the plate 38, and also spin about the respective central axes thereof, relative to the plate 38. Both gear pinions 40 are also in toothed engagement with the non-rotating sun gear 36, which defines the same central axis A as the main drive shaft 24. Thus, as the gear pinions 40 rotate about the central axis A, and because the sun gear 36 is non-rotating, the gear pinions 40 also spin about their own respective central axes, B, C (see Fig. 5).

[0025] As shown in Fig. 3, the planetary gear pinions 40 rotate about the central axis A within a tub 60 extending from the back plate 22a of the housing 22. The tub 60 includes lubricating fluid, e.g., oil (not shown), in the bottom half thereof, e.g., approximately 1" of lubricating fluid, such that as the gear pinions 40 rotate about the central axis A, at least some of the teeth of the gear pinions 40 are lubricated with each revolution about the central axis A, e.g., by dipping in the lubricating fluid. Because the gear pinions 40 also spin about their respective central axes B, C, at least some different teeth of the gear pinions 40 are lubricated with each revolution about the central axis A, thereby keeping substantially all of the teeth of the gear pinions 40 properly lubricated during operation, for increased longevity of the gear pinions 40. Alternatively, a lubricating fluid mist may be employed, spraying the lubricating fluid onto the gear pinions 40.

[0026] As shown in Figs. 3-6, two bevel gear drives 42, e.g., 2:1 bevel gear drives, are secured to opposing sides of the middle shaft portion 24b of the main drive shaft 24, e.g., via brackets 44. The bevel gear drives 42 are also secured to the front side 38b on the plate 38 at the opposing ends thereof. Alternatively, the bevel gear drives 42 may be securely attached to the main drive shaft 24 and the plate 38 via any of numerous different alternative securement means currently known, or that later become known. The two bevel gear drives 42 also rotate with the main drive shaft 24 and the plate 38 about the central axis A.

[0027] As should be understood by those of ordinary skill in the art, bevel gear drives change the direction of drive between two connected shafts by 90 degrees. As also should be understood, each bevel gear drive 42 is an individual, modular component set, pre- assembled with the necessary lubrication for the proper function and longevity of the operative components thereof. As shown best in Fig. 3, each bevel gear drive 42 includes a first shaft 42a, extending in a direction generally parallel to the central axis A. Each of the first shafts 42a extends through the plate 38 and is keyed to a respective planetary gear pinion 40. Accordingly, as each gear pinion 40 spins about the respective axis B, C, thereof, the respective first shaft 42a keyed thereto also spins about the respective axis B, C. Each bevel gear drive 42 also includes a second shaft 42b, extending in a direction generally perpendicular to the central axis A. The bevel gear drives 42 translate spinning of the first shafts 42a thereof about their respective central axes B, C, into spinning of the second shafts 42b thereof about their respective central axes D, E (see Figs. 3-6). As should be understood, axes D, E are oriented substantially perpendicularly to axes A, B, C (see Fig. 6).

[0028] As shown best in Fig. 4, each of the second shafts 42b is keyed to a respective rotating feed wheel 34. Thus, spinning of the second shafts 42b about their respective axis D, E, rotates the keyed feed wheel 34 about the respective axis D, E as well. The feed wheels 34 are located on opposing sides of the main drive shaft 24 and define an exterior circumferential surface having surface irregularities. For example, without limitation, the feed wheels 34 define a generally knurled circumferential surface 34a.

[0029] As shown best in Fig. 5, the middle shaft portion 24b of the main drive shaft 24 includes two generally arcuate apertures 32 on opposing sides of the middle shaft portion 24b, extending into the interior channel 24d. The arcuate apertures 32 are sized to each complement and receive an arcuate portion of a respective feed wheel 34. Thus, an arcuate portion of each of the feed wheels 34 extends into the interior channel 24d along the middle shaft portion 24b.

[0030] Therefore, as should be understood, the main drive shaft 24, as well as the modular components directed or indirectly attached thereto, i.e., the plate 38, the planetary gear pinions 40, the bevel gear drives 42 and the feed wheels 34, are rotatable together about the central axis A. Additionally, rotation of the planetary gear pinions 40 about the central axis A is accompanied by spinning of the planetary gear pinions 40 about their respective central axes B, C, (due to their engagement with the non-rotating sun gear 36), which drives, i.e., spins, the respective first shafts 42a of the bevel gear drives 42 about the central axes B, C, thereof. Such rotation is translated by the respective bevel gear drives 42 to spin the second shafts 42b about their respective central axes D, E, to, in turn, spin the respective feed wheels 34 about the respective central axes D, E, thereof, as well. Inside the interior channel 24d of the main drive shaft 24, the feed wheels 34 are distanced apart within the interior of the middle shaft portion 24b to grab and feed the rope R through the main drive shaft 24 (via the rotation thereabout about axes D, E, respectively), while also continuously crumpling the outside of the rope R along different sides thereof. The rotation of the main drive shaft 24 about axis A also functions to continuously twist the rope R.

[0031] At the front end of the main drive shaft 24, a dynamic balancing weight 48 is also mounted to the front shaft portion 24a, machined to balance the main drive shaft 24 and substantially prevent vibration of the main drive shaft 24 during rotation about the central axis A thereof. A cutter driving pulley 46 is also mounted to the front shaft portion 24a (forward of the driven pulley 30 as shown). The main drive shaft extends to an aperture 50 in the front plate 22b of the housing 22, out of which the rope R exits.

[0032] Referring now to Figs. 3 and 5-6, a rotary cutter assembly 52 is secured to the front plate 22b of the housing 22. The rotary cutter assembly includes a shaft 54 extending through the front plate 22b, and rotatable relative thereto with minimal friction, e.g., via a bearing. A rotary blade 56 is keyed proximate a front end of the shaft 54 (outside the housing 22) to rotate therewith. The span of the rotary blade 56 overlies the aperture 50, in order to cut the rope R as it exits from the aperture 50. Inside the housing 22, a cutter driven pulley 58 is also keyed to the shaft 54. The cutter pulleys 46, 58 are linked together by a timing belt (not shown) extending around both pulleys 46, 58. Accordingly, rotation of the driving pulley 46 about the central axis A thereof (along with rotation of the main drive shaft 24), drives rotation of the driven pulley 58 about the central axis F thereof, thereby rotating the entire rotary cutter assembly shaft 54, including the rotary blade 56, about the central axis F. As should be understood, the respective diameter of each of the two pulleys 46, 58 is sized relative to one another such that the rotary cutter assembly shaft 52 is rotated about the central axis F thereof at the desired rpm to cut the desired about of dunnage nuts per minute. As also should be understood the rotary blade 56 may be a single arm having one cutting surface 56a or a single arm having two cutting surfaces 56a, the two cutting surfaces 56a forming dunnage nuts that are half the length of dunnage nuts formed by a single cutting surface 56a.

[0033] In operation, paper is pulled from a roll S through the cone 16, the elbow tube 18 and advances through the extension member 20 of the infeed system 12. The paper is pulled into the machine 14 through the exit aperture 20c of the extension member 20 and the aperture 37 of the back plate 22a and into the interior channel 24d of the main drive shaft 24 by the feed wheels 34. As explained above, the main drive shaft 24 spins about the central axis A thereof. Spinning of the main drive shaft 24 about the central axis A twists the paper in the extension member 20 into a rope R. Rotation of the first, second and third roller bearing assemblies 20d, 20a, 20b about the central axis A in the extension member 20 permits the paper to twist into a rope R in the extension member 20 without tearing. Spinning of the main drive shaft 24 also causes the planetary gear pinions 40, rotating with the main drive shaft 24 about the central axis A to also spin about their respective central axes B, C (due to their toothed engagement with stationary, non-rotating sun gear 36). Spinning of the gear pinions 40 about the respective central axes B, C thereof, drives the bevel gear drives 42 to spin the feed wheels 34 and the respective central axes D, E thereof. The spinning feed wheels 34 continuously grab and pull the rope R through the main drive shaft 24, while also continuously crumpling the outside of the rope R along different sides thereof. The rotation of the main drive shaft 24 about axis A also continues to twist the rope R. The rope R exits the interior channel 24d at the aperture 50 in the front plate 22b of the housing 22, and is periodically cut by the rotary blade 56 to generate dunnage nuts. The rotary cutting blade 56 is also driven by the rotation of the main drive shaft 24.

[0034] It will be appreciated by those skilled in the art that changes could be made to the embodiment described above without departing from the broad inventive concept thereof. For example, without limitation, the dunnage producing machine 14 may utilize a friction disk and wheel assembly (as should be understood by those of ordinary skill in the art) to rotate the main drive shaft 24 about axis A instead of, or in combination with, the gear and timing belt assembly described herein. A friction disk and wheel assembly provides the benefits of a quiet, maintenance-free operation, simplified replacement and/or servicing, and adjustment to the rotation speed of the main drive shaft 24 to enable producing dunnage nuts of varying twist tightness. Accordingly, the formed dunnage nuts may define a tightly twisted cylindrical shape or a loosely twisted shape, according to the desired application. Moreover, the dunnage producing machine 14 may include a stitching mechanism, such as, for example, at least one stitching feed wheel, to stitch the formed dunnage nuts to prevent untwisting thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the appended claims.