Abstract:
The preferred embodiment of a dunnage apparatus includes a crumpling device configured for crumpling sheets of paper to produce low-density packaging dunnage. A paper feeder is provided to feed feeding sheets of paper into the crumpling device for crumpling.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of International Application No. PCT/US2008/074907, filed Aug. 29, 2008, entitled “SHEET-FED DUNNAGE APPARATUS” and claims priority benefit of U.S. Provisional Patent Application No. 60/966,952, filed Aug. 31, 2007, entitled, “SINGLE SHEET FEED AND CRUMPLING APPARATUS,” the contents of which applications are hereby incorporated herein by reference thereto. 
    
    
     TECHNICAL FIELD 
     The present subject matter relates generally to an apparatus for producing dunnage for protective packaging. 
     BACKGROUND 
     Products to be transported and/or stored often are packed within a box or other container. In many instances, however, the shape of the product does not match the shape of the container. Most containers utilized for transporting products have the general shape of a square or rectangular box and, of course, products can be any shape or size. To fit a product within a container and to safely transport and/or store the product without damage to the product, the void space within the container is typically filled with a packing or cushioning material. The packing material utilized to fill void space within a container is often a lightweight, air-filled material that may act as a pillow or cushion to protect the product within the container. In many circumstances, a plastic bubble material is utilized to protect and cushion the product contained within a container. 
     Small Styrofoam nuggets or “peanuts” may also be utilized to fill void space within containers for protecting and cushioning a product within a container during transport and/or storage. These nuggets or “peanuts” normally need to entirely fill the void space within the container to adequately protect the packaged product. In addition, it is also difficult to contain the Styrofoam nuggets or “peanuts” within the container, especially after the container has been opened. 
     Another typical material utilized for filling void space within containers, and for protecting and cushioning a product contained within the container, is paper and/or paper substrates. Typically, sheets of paper material can be crumpled so as to form long shapes having many folds or pleats. Lengths of crumpled paper can be created to easily and effectively fill void space within a container holding a product. Because the paper has fold spaces and/or pleats, the crumpled paper can be very effective at protecting and cushioning a product contained within the container, and may effectively prevent damage to the product during transport and/or storage. 
     Sheets of paper may be crumpled by hand, in that a person may take a length of a sheet of paper, and crumple the paper to form various shapes to fill void space within a container to protect and cushion a product contained therein. Hand crumpling paper takes much time, and is not effective and/or efficient to provide a large amount of crumpled paper as may be needed in a production line. Machines, therefore, are used to crumple paper. 
     Typical machines utilized to crumple paper generally take a length of a sheet of paper, and feed the paper into a crumpling zone of the machine to provide a crumpled paper product. Long sheets of paper substrate material are typically provided on rolls and are fed into machines at a high rate of speed. Certain issues must be overcome when using rolls to control the rate of speed for the paper substrate to be removed from the roll, which often is done with a braking mechanism to prevent the roll from unwinds at a higher rate of speed than the paper is being fed into the machine, which can cause paper to spill off the roll. This can occur when the rate of feeding of the paper into the crumpling machine slows, and momentum causes the roll, which is heavy with paper, to continue rolling. Using a roll also requires a cutting mechanism to cut the desired lengths of crumpled paper. 
     A need, therefore, exists for a dunnage apparatus that can allow improved operation feeding and/or crumpling mechanism made from relatively soft materials that may solve the problems associated with utilizing metal in the feeding and/or crumpling mechanisms. 
     SUMMARY 
     The present subject matter relates generally to an apparatus for crumpling paper sheeting for use in packaging. To this end, in an embodiment of the present invention, a dunnage apparatus is provided comprising a crumpling device configured for crumpling sheets of a substrate to produce low-density packaging dunnage, and a feeder configured for feeding separate sheets of the substrate paper into the crumpling device for crumpling. 
     The paper feeder can be configured for feeding the sheets from a stack to the crumpling device, and for feeding individual sheets to the crumpling device. The paper feeder can feed more than one of the sheets at a time in an overlapping arrangement into the crumpling device. 
     The dunnage preferably comprises a supply tray configured and dimensioned for holding the sheets arranged as a stack, wherein the paper feeder is disposed and configured for feeding the sheets of paper from the supply tray to the crumpling device. The paper feeder can be configured for drawing the sheets from the top of the stack to the crumpling device. The paper feeder can comprise a drive roller positioned to engage a sheet on the surface of the stack for feeding the sheets. The paper feeder and the tray can be associated movably to accommodate a varying thickness of the stack. 
     In the preferred embodiment, the dunnage apparatus has a feed guide disposed for cooperating with the paper feeder for guiding the sheets into the crumpling device. The feed guide can be movable with respect to the paper feeder and crumpling device to accommodate a varying thickness of the stack. The feed guide can be disposed for engaging an opposite surface of the sheets than the paper feeder. 
     The crumpling device can be configured for forming crumples in the paper that are oriented generally in a direction transverse to a direction of travel of the paper through the crumpling device. The crumpling device comprises upstream and downstream engagement elements defining a crumple zone therebetween, wherein the upstream engagement element is configured for forcing the paper into the crumple zone, and the downstream element is configured for restricting movement out of the crumple zone for creating the crumples. The upstream element can comprise a driven roller, and the downstream element can comprise non-rotating restriction members causing the paper to bunch up in the crumple zone. The restriction members can be movable to release the crumpled paper from the crumple zone. The restriction members can comprise fingers biased against each other for restricting the flow of paper out of the crumple zone but to release the paper once a pushing force of the paper being fed from the upstream element rises to a threshold. 
     A paper supply support can be provided for supporting a paper container that contains the sheets arranged as a stack, wherein the paper feeder is configured for drawing the sheets out of the supply container for feeding into the crumpling device. The apparatus preferably accepts a container, which has a removable closure to expose a side of the stack to enable the paper feeder to feed the paper from the container to the crumpling device. The container can be formed as an at least semi-rigid box. 
     A preferred dunnage accumulator of the apparatus is associated with the crumpling device for receiving and storing the crumpled dunnage for access by a user. The dunnage accumulator can comprise at least a pair of rails or rods extending in downstream direction from the crumpling device. The dunnage accumulator can be configured for supporting the dunnage on sides thereof, preferably the lateral sides thereof, and defines an extraction opening between the sides to enable the dunnage to be removed from the accumulator by pulling the dunnage downwards from below the extraction opening. In embodiments that employ rails, these can be spaced from each other to define the extraction opening. 
     A dunnage apparatus is also provided, comprising a crumpling device that can be configured for crumpling paper to produce low-density packaging dunnage, and a dunnage accumulator disposed downstream of the crumpling device for receiving and storing crumpled dunnage, wherein the dunnage accumulator can be configured for supporting the dunnage on sides thereof and defines an opening between the sides to enable the dunnage to be removed from the dunnage accumulator by a user pulling the dunnage downwards from below the opening. 
     Also provided is a method of producing dunnage, comprising the steps of feeding separate sheets of paper into a crumpling device, and crumpling the sheets of paper in the crumpling device to produce low-density packaging dunnage. 
     The present subject matter allows a plurality of single sheets of paper or other substrate to be fed into a crumpling apparatus for crumpling each individual sheet, or groups of separate sheets, of paper or other substrate. The apparatus provides precise feeding of each individual piece of paper or other substrate. Moreover, the apparatus provides individual crumpled sheets to be utilized in packaging to be used as dunnage for the protection of products contained therein. 
     Additional advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements. 
         FIG. 1  is a perspective view of an embodiment of a dunnage apparatus; 
         FIG. 2  is a perspective view of a paper feeder thereof; 
         FIG. 3  is a perspective view of a supply tray and a paper stack supply box thereof; 
         FIG. 4  is a side view of a finger of an embodiment of the crumpling apparatus; 
         FIG. 5  is a side view of another embodiment of the crumpling apparatus; 
         FIG. 6  is a side view of another embodiment of the crumpling apparatus; and 
         FIG. 7  is a perspective view of a box of paper used with the crumpling apparatus. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present subject matter relates generally to an apparatus for crumpling paper sheeting for use in packaging. More specifically, the present subject matter relates to an apparatus for feeding separate pieces or sheets of paper or other substrate into a crumpling apparatus and crumpling the same. 
     Now referring to the embodiment crumpling apparatus  10  of  FIG. 1 , the preferred substrate from which the dunnage is produced is paper, although other suitable substrates can be employed. Dunnage apparatus  10  comprises a paper feeder  20 , a tray/table  30  and a paper crumpler  40 . The dunnage apparatus  10  can include a floor stand  11 , having a support for holding the tray  30 . Removable support bar  81  can be disconnected to allow the paper feeder  20  to be opened in case of a paper jam. The preferred tray  30  holds individual sheets of paper, which can be stacked, or can hold a box having sheets of paper in it (or other suitable substrate), as will be explained below. In an alternative embodiment, another support can be used for the supply of material to be crumpled. 
     The feeder  20  feeds paper from the tray  30  into the crumpler  40 . The crumpled paper  16  is received by guides  15  when the paper exits the paper crumpler  40 . 
     As shown in  FIG. 2 , the preferred paper feeder  20  has a housing  28  and comprises a drive roller assembly  21  that feeds individual sheets of paper to a pinch roller assembly  22 . The drive roller assembly  21  pulls individual sheets of paper from an infeed side  25  from the tray  30  and towards the pinch rollers  22  and over an infeed guide  23 , which is preferably has a sloped surface to help guide the individual sheets of paper. The drive roller assembly  21  is associated with a motor (not shown) for driving the drive rollers  21   a ,  21   b.    
     In the preferred embodiment, the infeed guide  23  is associated with the drive rollers  21   a ,  21   b  so that the guide  23  and the drive rollers  21   a ,  21   b  move towards or away from each other to adjust the space therebetween according to the changing thickness of stack. Such movement is preferably orthogonal to the direction of flow of sheets along the path through the device. The drive rollers  21   a ,  21   b  can move vertically by means of an attachment  26  to maintain contact with the paper sheets, so that as the sheets are drawn off a stack, the drive rollers  21   a ,  21   b  may move vertically downwards to maintain contact with the paper sheets  16 , as shown in  FIG. 3 . In the preferred embodiment, the infeed guide  23  also or alternatively can move vertically, and can have a longitudinal end, preferably the upstream side that faces the tray, to raise the height of the sheet or sheets being fed into the crumpler  40  to ensure that they are taken up for example by the pinch rollers  22   a ,  22   b . Preferably, as the drive rollers  21   a ,  21   b  move vertically, so does the infeed guide  23 , but in the opposite direction, to ensure that the paper sheeting is properly fed into the pinch roller assembly  22 . The infeed guide  23  is positioned in one embodiment in front of the tray  30 , as shown in the embodiment of  FIG. 5 . In another embodiment, the guide  23  is positioned under the front end of the stack  60  or box  32 , as shown in  FIG. 6 , to lift the stack  60  or box  32  to the desired height. In another embodiment, the tray  30  is movable up and down to position the fed sheets  16  and stack  60  as desired. 
     The pinch roller assembly  22  can also be interconnected with the same or a different motor (not shown) and further provide continuous movement of the sheet(s) into the paper crumpler  40 . The pinch roller can comprise one pinch roller  22   a  or more than one pinch rollers  22   a ,  22   b , where one or both of the pinch rollers  22   a ,  22   b  may be interconnected with the motor for feeding paper sheets therethrough. Other mechanisms can alternatively be employed to take up the sheets  16  from the feeder  20 . The pinch roller assembly  22  is preferably also used to force the sheets  16  into a crumple zone in which they are crumpled, as described below. In the preferred embodiment, one of the pinch rollers  22   a ,  22   b  is interconnected with the motor, such that movement of one pinch roller causes movement of the second pinch roller, due to the contact of the one pinch roller with the second pinch roller. The undriven pinch roller  22   b  can also be replaced with a suitable support element against which the driven pinch roller  22   a  can press and move the sheets. 
     In  FIG. 3 , a tray  30  is shown holding a container for the supply sheets  16 , which is preferably a box  32  or corrugated cardboard or other suitable material. The container can alternatively be a soft envelope of paper or other suitable material, but is preferably at least semi-rigid to help maintain the alignment of the stack regardless of handling and the current thickness of the stack. 
     Although paper sheets  16  may be placed directly onto the tray, the corrugated box  32  having a access opening  33 . With the box  32  placed on the tray, the drive rollers  21   a ,  21   b  come in direct contact with the exposed paper  16  of the stack  60  through the access opening  33 , allowing the paper  16  to be fed into the apparatus  10 . The opening is preferably covered by a tear-away portion of the box  32  to allow for a quick and easy restocking of the tray  30  once the paper is finished and a fresh box  32  is placed on the tray. Preferably, the tear-away portion  70  is connected to the remainder of the box  32  with a perforated line  71  configured to expose the access opening, to expose one of the end-sheets in the stack, as well as the downstream side  72  of the box  32 . 
     The tray  30  allows a box of single sheet paper of suitable size, and preferably of roughly 24″×18″, although other dimensions can be utilized, as will be apparent to one having ordinary skill in the art, to be fed into the drive roller  21  and pinch roller assembly  22 . It should be noted that any size paper sheeting, or other substrate, is contemplated by the present invention, although paper is preferred. In one embodiment, the sheeting is around 24″×48″. The sheeting may be smaller or larger, such as up to a full pallet size (about 40″×48″), although larger sheets can be used in other embodiments. Moreover, the paper sheeting may be of various densities, such as between 20 lb and 70 lb. Kraft paper. The paper sheeting may be virgin or recycled. Moreover, the paper sheeting may be intermixed so as to deliver 2 sheets or more at once of the same basis weight, or a combination of basis weights. As shown in  FIG. 1 , the tray is preferably inclined to naturally hold the box  32  in place using rear walls  35  and side tray walls  31  using gravity. Other orientations can alternatively be used. 
     The crumpler  40  can comprise a plurality of fingers  41  disposed downstream of the pinch roller assembly  22 . As shown in  FIG. 4 , the fingers  41  preferably extend longitudinally, and distributed laterally across the outlet of the crumpler  40 , and are inclined and preferably curved towards the crumpled sheet  16  to create a blockade that blocks the exit for the sheeting, whereby the sheeting crumples as it is fed into the crumpling zone  55  by the pinch rollers  22   a ,  22   b , which is located in this embodiment between the pinch rollers  22   a ,  22   b  and the fingers  41 . Some of the fingers  41 , preferably the top section  42  of fingers  41 , is preferably fixed, with opposing fingers  41 , preferably the bottom section  43  of fingers  41 , are preferably spring-loaded or otherwise mechanically inclined to allow the bottom section  43  to open or rotate away from the top section  42  when the pushing force of the paper by the pinch rollers rises to a threshold. 
     The crumpled paper  16  is then ejected onto a dunnage accumulator  51  with a receiving surface such as rails  15  or other supports, to preferably accumulate in an accumulation zone  50 . The rails  15  or supports are preferably formed of rails, such as made of rods, or another structure to define an extraction opening  80  to allow the accumulated, crumpled sheets to be discharged from the accumulation zone  50  by pulling down on them from between the rails  15 . In this manner, the dunnage apparatus  10  can be located overhead on a packaging line, and the user can reach up and pull individual lengths of accumulated, crumpled, sheet dunnage to place in a package about an item to be protected. Each such length would typically be in the shape of a bar or log of paper where separate sheets are used as the paper supply. The dunnage accumulator in another embodiment can be used with a traditional roll-fed crumpling mechanism. 
     In the preferred embodiments, the crumpling device  40  is configured to form crumples in the paper  16  that, along with their peaks and valleys, are oriented generally in a direction transverse than a direction of travel of the paper  16  through the crumpling device  40 , as shown in  FIG. 1 . The direction from peak to peak in this embodiment is thus generally aligned longitudinally. Other embodiments can crumple the paper in a different direction, such as with the crumples oriented longitudinally or at an angle to the direction of travel of the paper. 
     In the embodiment shown in  FIG. 5 , the crumpling mechanism  40  has a downstream portion that uses one or more roller assembly  51  with rollers  51   a ,  51   b  that rotate at a slower speed than the upstream rollers  52   a ,  52   b  of an upstream roller assembly. This causes the sheets  16  to crumple in crumpling zone  55 , which are thus discharged from downstream roller assembly  51  as crumpled dunnage. 
     All of the references specifically identified in the detailed description section of the present application are expressly incorporated herein in their entirety by reference thereto. The term “about,” as used herein, should generally be understood to refer to both the corresponding number and a range of numbers. Moreover, all numerical ranges herein should be understood to include each whole integer within the range. 
     While illustrative embodiments of the invention are disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the features for the various embodiments can be used in other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention.