Patent Publication Number: US-9403612-B2

Title: Manually-assisted void-fill dunnage dispensing system and method

Description:
This application is a national phase of International Application No. PCT/US2009/038501, filed Mar. 27, 2009, and published in the English language under Publication No. WO 2009/123919, which claims the benefit of U.S. Provisional Patent Application No. 61/040,942, filed Mar. 31, 2008, which are incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention is directed to a relatively inexpensive packaging system and method for dispensing an appropriate amount of void-fill dunnage to fill a void in a container. 
     BACKGROUND 
     In the process of packing one or more objects in a container for shipment, a void-fill dunnage product typically is placed in the shipping container along with the objects, partially or completely filling the empty space around the objects in the container to prevent or minimize shifting during the shipping process. Some commonly used void-fill dunnage materials include plastic foam peanuts, plastic bubble wrap, airbags, and converted paper dunnage. Some of these dunnage products take up a lot of space unless converted from a more compact stock material as needed. 
     Typically, a packer looks into a container in which one or more objects have been placed for shipment and determines the amount of dunnage material needed to fill the remaining void in the container. The packer then controls a dunnage dispenser to dispense the desired amount of dunnage. For strip-like dunnage products, an experienced packer can quickly determine how many and what lengths of dunnage strips are needed to fill the void in the container. 
     An inexperienced packer, however, has much more difficulty determining what lengths and what number of strips of dunnage are needed to fill the void volume. Consequently an inexperienced packer sometimes slows the packing process and is less efficient than an experienced packer. To avoid this problem, automated systems have been developed to measure the void volume in a container and then automatically determine the required dunnage strips for the packer. In some cases these systems remove the need for a packer altogether. The initial cost of a fully automated system generally is greater than that for a packer-operated system. 
     SUMMARY 
     The present invention provides an inexpensive solution to the inexperienced packer problem while providing appropriate lengths of void-fill dunnage for a wide variety of container sizes and product configurations. 
     An exemplary method according to the invention includes the step of manually selecting an input option from multiple input options. The input options represent relative degrees to which a container is filled by one or more objects to be packaged. The method also includes the steps of identifying one or more characteristics of a container, and providing an output signal indicating the quantity of dunnage to dispense to the container based on the selected input option and the one or more characteristics of the container. 
     Even an inexperienced packer can look at a container having one or more objects placed therein for shipping and select the input option that best represents the relative degree to which the container is filled. Once the characteristics of the container have been identified, and the packer has selected the best input option representing the relative degree to which the container is filled, a controller can determine the quantity of dunnage to dispense to fill the void in the container. Since void-fill dunnage typically has resilient properties that enable it to be slightly compressed without destroying its intended function, and since the void-fill dunnage does not need to fill the void absolutely completely, the packer&#39;s selected relative degree of fill typically is sufficient for the controller to determine an adequate amount of dunnage. 
     Accordingly, an exemplary void-fill packaging system includes a manual input device for selecting the input option representing the relative degree to which a container is filled by the one or more objects to be packaged, an input device that identifies one or more characteristics of the container, and a controller that provides an output signal indicating a quantity of dunnage to be dispensed to the container based on the selected input option and the one or more identified characteristics of the container. 
     The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail several illustrative embodiments of the invention, such being indicative, however, of but a few of the various ways in which the principles of the invention may be employed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic representation of a packaging system provided in accordance with the present invention; and 
         FIG. 2  is a schematic representation of an exemplary packaging system provided in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention provides an inexpensive solution to the problem of an inexperienced packer. Yet the present invention provides a system that can supply an appropriate length of void-fill dunnage for a wide variety of container sizes and product configurations. An inexperienced packer, even without knowing anything about the dunnage product being dispensed, can look at a container having one or more objects placed therein for shipping and can select the input option that best represents the relative degree to which the container is filled. Once the characteristics of the container have been identified, and the packer has selected the input option representing the relative degree to which the container is filled, a controller can determine the quantity of dunnage to dispense to fill the void in the container. This allows an inexperienced packer to effectively assist in determining the appropriate amount of dunnage to dispense, even when the packer has never performed the task before. Additionally, since void-fill dunnage typically has resilient properties that enable it to be slightly compressed without destroying its intended function, and since the void-fill dunnage does not need to fill the void absolutely completely to be effective, the packer&#39;s selected relative degree of fill typically is sufficient for the controller to determine an adequate amount of dunnage. 
     Briefly, the present invention provides a packaging system that includes means for manually selecting an input option from multiple input options, where the input options represent relative degrees to which a container is filled by one or more objects to be packaged, or means for manually inputting a relative degree to which a container is filled with one or more objects to be packaged. The packaging system also includes means for identifying one or more characteristics of the container, and means for providing an output signal indicating the quantity of dunnage to dispense to the container based on the selected input option and the one or more identified characteristics of the container. Alternatively, the system can include a means for outputting a signal indicating the quantity of dunnage to dispense based on the manually input relative degree of fill and the identified characteristics of the container. 
     Referring now to the drawings and initially to  FIG. 1 , the present invention provides a packaging system  100  that includes a controller  102 , an input device  104  in communication with the controller  102  that identifies one or more characteristics of the container, and a manual input device  106  in communication with the controller  102  that provides multiple input options for selection by a packer. The input options represent relative degrees to which a container has been filled by one or more objects to be packaged. The relative degree of fill is an estimate or approximation of how full the container is, such as nearly empty, half full, and nearly full. The controller  102  provides an output signal indicating a quantity of dunnage to dispense to the container based on the selected input option and the one or more identified characteristics of the container. 
     The container characteristics can include one or more of a container identifier, a size, shape, and/or one or more dimensions of the container. The container identifier can include a barcode, name, number, color, radio frequency identification (RFID) or other indicia that can be used by the controller to identify the container and/or its unfilled or empty volume. 
     Once the controller  102  receives the container characteristics information, as well as the selected input option representing the relative degree to which the container is filled by the objects to be packaged, the controller  102  can determine the number and lengths of dunnage strips that need to be provided to fill the remaining void in the container. This can be accomplished in many ways. For example, once a container is identified, the controller  102  can calculate the void volume when the container is empty, and then using the approximate degree of fill provided by the packer, the controller  102  can calculate how much volume remains in the container that needs to be filled. If the approximate volume taken up by the dunnage is known, the controller  102  can calculate an amount of dunnage adequate to fill the void. Rather than calculating the void volume, the controller could look the information up in one or more look-up tables. For each container, for example container sizes A, B, and C, the look-up table may include the appropriate amount of dunnage to dispense depending on whether the container is nearly empty, half full, or nearly full. 
     Once the controller  102  has determined the amount of dunnage that needs to be dispensed, the controller can signal a dunnage dispenser  110  to dispense the determined amount of dunnage. The controller  102  can be integrated into the dunnage dispenser  110 , or can be remotely located relative to the dunnage dispenser  110 , and can either control the dispenser  110  remotely or communicate the amount of dunnage to be dispensed to another controller that is integrated into the dispenser  110 . 
     An exemplary packaging system  200  provided in accordance with the present invention is illustrated in  FIG. 2 . The packaging system  200  includes a controller  202 , a container characteristics input device  204 , a manual input device  206 , and a dunnage dispenser  210 . An exemplary dunnage dispenser  210  is a void-fill dunnage conversion machine  214  that converts a sheet stock material  216  into a thicker and relatively less dense void-fill dunnage product  220 , such as the conversion machine disclosed in U.S. Pat. No. 6,676,589, which is hereby incorporate herein by reference. An exemplary supply  222  of sheet stock material includes a stack of fan-folded kraft paper, such as that shown mounted on a stand  224  for the conversion machine  214 , or a roll of one or more plies of sheet stock material. 
     The dunnage conversion  214  machine can be positioned adjacent a packaging surface, such as the illustrated conveyor  230 , for dispensing packaging material to a container  232  on the packaging surface. An exemplary container  232  is a cardboard box, typically in the form of either a rectangular slotted container (RSC) with inwardly folding flaps, or a shoebox-style container with a separate lid. The controller  202  is integral to the dunnage conversion machine  214  and not only determines the amount of dunnage to dispense but also signals the conversion components of the machine to produce the determined amount of dunnage. The controller  202  includes a processor  234  and a memory  236  for storing programming and data needed to determine the amount of dunnage to dispense and to control the dunnage dispenser  210  or elements thereof to dispense the determined amount of dunnage, such as the number of and the lengths of dunnage strips, based on the container characteristics inputs and relative degree of fill inputs. 
     The container input device  204  includes at least one of a barcode reader, one or more sensors to indicate dimensions of the container  232 , a mechanical, optical or electromagnetic probe, a computer mouse, a touch screen display, a keypad, a push-button switch, a toggle switch, a foot switch, a rotary dial, a kneepad switch, a wireless remote control device, a radio frequency identification (RFID) reader, and a stylus and stylus-sensitive pad or any other means for inputting container characteristics. As noted above, the container input device  204  identifies the container  232 , the dimensions of the container, its size or other characteristics that will enable the controller  202  to determine the appropriate amount of dunnage to dispense. The container characteristics can be input in many different ways, either manually by a packer or automatically. One way to input the container characteristics includes reading a barcode, which the controller  202  will then look up in a look-up table to determine the amount of dunnage to dispense based on the barcode-identified container characteristics and the manually-selected degree-of-fill input option for that container. Alternatively, the controller  202  can calculate the void volume of an empty container and then determine how much of that void remains based on the selected manual input option provided by the packer. 
     The manual input device  206  can include one or more of a microphone, a computer mouse, a touch screen, a keypad, a rotary dial, a push-button, a switch, a foot switch, a kneepad switch, a wireless remote control device, a toggle slider, and a stylus and stylus-type sensitive pad or any other means for inputting a selected relative degree of fill for a container. The manual input device  206  provides input options between empty and full. Typically, the manual input device  206  provides about two to about five discrete input options. Some input devices, however, can provide an infinite number of options, limited only by the sensitivity of the input device. A slider, for example, can provide a continuum of options between empty and full and the operator can move the slider to the position that best represents the relative degree to which the container is filed. The same type of input can be provided via a touch screen. Alternatively, the input can be provided by the number of times a switch is triggered, or by triggering a particular switch among a plurality of switches provided. 
     Additionally, the manual input device  206  and the container characteristics input device  204  can be embodied in the same device. Accordingly, the packer could first read a box code into a microphone to identify the container and then select the relative degree of fill by speaking into the same microphone. The controller in that case can include voice recognition software to identify the words spoken and match them to known containers and degrees of fill. Such a system can be calibrated for different users, such as at the beginning of each shift, by having the packer recite the available options. 
     For discrete input options, exemplary input options include empty  240 , 25% full  242 , 50% full  244 , 75% full  246 , and full  250 , which are shown in the illustrated embodiment as graphical representations with means for selecting the desired input option, such as a push-button switch or designated area of a touch screen. Alternatively, the input options may forego including empty and full as options, since an empty container and a full container probably will not require void-full dunnage. An empty container is likely to be an error or a fault condition that would require correction prior to dispensing dunnage thereto. A full container is a container that generally can be passed along for shipment without dispensing any void-full dunnage material thereto. 
     Another alternative set of input options can include nearly empty, half full, and nearly full. These are all relative degrees of fill that an experienced packer, or perhaps even a child, could identify by looking into a container without having any prior experience in providing dunnage material to a container for shipment. Additionally, as noted above, the manual input device  206  can include a linearly-variable level indicator with settings between empty and full, such as the slider mentioned above. The controller  202  then can use the selected manual input option and the container characteristics input to determine the amount of dunnage to dispense and instruct the conversion machine  214  to produce the determined amount of dunnage. 
     The dunnage conversion machine  214  or other dunnage dispenser can further include a dunnage dispensing input device  260 , such as the illustrated foot switch, to manually dispense an additional amount of dunnage if the packer determines that the amount of dunnage determined by the controller  202  and dispensed from the dispenser  210  is insufficient to fill the void in the container  232 . The manual dunnage dispensing input device  260  does not have to be a separate device, but can be the same device used as one or both of the manual input device  206  and the container characteristics input device  204 . 
     An exemplary method provided in accordance with the present invention, includes the steps of (i) manually selecting an input option from multiple input options, where the input options represent relative degrees to which a container is filled by one or more products to be packaged, (ii) identifying one or more characteristics of a container, and (iii) providing an output signal indicating a quantity of dunnage to dispense to the container based on the selected input option and the one or more identified characteristics of the container. The selecting step can be performed manually by at least one of speaking into a microphone, pressing a button, moving a toggle switch or rotary dial, typing on a keypad, pressing a foot switch or a knee switch, touching a touch screen display, moving a slider switch, and clicking a computer mouse. Touching the touch screen display can include touching one or more areas of a touch screen display to select a discrete option or select from a linear range of options. The identifying step can include reading a bar code, reading a radio frequency identification tag (RFID tag), speaking into a microphone, sensing a dimension, pressing a button, moving a toggle switch or rotary dial, typing on a keypad, pressing a foot switch or a knee switch, and clicking a computer mouse. 
     The providing step includes transmitting the output signal to a dunnage dispenser or components thereof to dispense the indicated quantity of dunnage. Accordingly, the providing step can include transmitting the output signal to a dunnage conversion machine or components thereof to convert a stock material into a dunnage product to dispense the indicated quantity of dunnage. 
     The selecting step can include selecting from about two to about five discrete input options, or an input option from a range of linear continuous input options. The selecting step ca include selecting from discrete input options that include empty, 25% full, 50% full, 75% full, and full. Alternatively, the selecting step can include selecting from discrete input options that include nearly empty, half full, and nearly full. The method also can includes the step of manually dispensing an additional amount of dunnage. 
     As should be apparent from the description provided herein, the present invention provides a packaging system that an inexperienced packer can immediately operate and contribute to a company&#39;s packaging operation without requiring a lot of experience or training to do so effectively. 
     Although the invention has been shown and described with respect to a certain embodiment or embodiments, equivalent alterations and modifications will occur to others skilled in the 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 illustrated exemplary embodiment of the invention.