Adjustable Folding Roller Machine for Adaptable Pop-Up Wipe Formats
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional machines for producing stacks of folded wipes are inflexible, require significant reconfiguration and replacement of components to change formats or directions, and often result in limited capacity and ply buildup, especially when producing narrow width stacks or multiple direction folds.
Innovation Solution
A machine with a folding unit comprising adjustable grippers and infeed plates, controlled by a processor to adapt the distance between them, allowing for flexible production of various formats and directions using a single path, and a control unit that synchronizes the angular velocity of rollers to achieve adaptable folding patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional machines use separate material paths for each wipe in a stack, then folding and interlocking can be achieved, but the machine requires a large footprint and a large number of components that need replacement when reconfiguring
Solution Approach 1:
The patent merges multiple separate material paths into a single integrated path where wipes are folded and interlocked sequentially. The folding unit combines multiple folding operations and the interlocking mechanism into one unified system that processes all wipes through a single material path, eliminating the need for separate paths for each wipe.
Solution Approach 2:
The folding unit is designed as a universal component that can handle different wipe formats and stacking configurations through a single material path. The adjustable folding rollers and interlocking mechanism can adapt to various production requirements, replacing the need for multiple specialized components.
2Adaptability or versatility
If conventional machines are reconfigured to produce different stack or wipe formats, then production flexibility can be improved, but substantial re-build and replacement of components is required
Solution Approach 1:
The folding rollers are designed with adjustable positions and angles, allowing dynamic reconfiguration for different wipe formats. The interlocking mechanism can be adjusted to accommodate varying stack heights and configurations, enabling flexible production changes without substantial re-builds.
Solution Approach 2:
The machine allows parameter changes such as adjusting roller positions, folding angles, and interlocking depths to produce different stack formats. These parameter adjustments enable format changes without requiring component replacement, improving ease of reconfiguration.
3Quantity of substance
If conventional machines produce stacks with relatively narrow width, then stack density is improved, but ply buildup occurs
Solution Approach 1:
The interlocking mechanism incorporates vibration or oscillation to prevent ply buildup during the folding and stacking process. This mechanical action helps maintain smooth ply separation and prevents accumulation, allowing narrow width stacks to be produced without the harmful effect of ply buildup.
4Quantity of substance
If conventional machines increase the number of material holders to produce more wipes in a stack, then stack capacity is improved, but the number of components that need replacement during reconfiguring increases
Solution Approach 1:
The patent processes multiple wipes through a single material path using one set of material holders, combining the functionality of multiple separate paths into one unified system. This maintains stack capacity while reducing the number of material holders from multiple per wipe to a single shared set.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The disclosure relates to a machine (100) configured to produce stacks of folded pop-up wipes (192) from material (110), wherein the material (110) is threaded along a path (112) through the machine (100), the machine comprising: a holder (111) of the section of material (110), a first tension unit (160), a folding unit (180), the folding unit (180) comprising: two or more folding rollers (350, 360) configured to receive a section of the material (110) and generate folded stacks of pop-up wipes (192) having an adaptable format, wherein each folding roller (350, 360) comprises: a hub (301, 302), wherein the hub (301, 302) comprises one or more grippers (331, 332, 341, 342) configured to grip and release the material (110), and one or more infeed plates (321, 322, 323, 324) configured to feed the tissue (110) to respective grippers (331, 332, 341, 342) of the other roller, wherein positions of the one or more infeed plates (321, 322, 323, 324) are configured to be adjustable in relation to positions of the respective grippers (331, 332, 341, 342), wherein distances between the grippers and the respective infeed plates adapts a width (w) of the produced stacks of wipes (192), a control unit (CU) communicatively coupled to at least the first tension unit (160) and the folding unit (180), the control unit (CU) comprising a processor, and a memory, said memory containing instructions executable by said processor, wherein the material (110) is threaded along a path (112) through the machine (100) via at least the first tension unit (160) and the folding unit (180), wherein executing the instructions by the control unit (CU) causes the control unit (CU) to control the machine to perform the method herein.