Duckbill Mask Multi-Line Machining Process
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Solution Overview
Problem
Existing duckbill mask manufacturing processes are inefficient, resulting in low production capacity and significant material waste due to the use of single-line machining and linear arrangement of masks.
Innovation Solution
A multi-line machining process is introduced, featuring multi-line edge folding and press sealing, overlapping, and finished product cutting to produce duckbill masks, along with a staggered opposite arrangement method and double-way staggered cutting technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-line machining process is used, then the device complexity is reduced, but the productivity decreases to 45-60 pieces/min
Solution Approach 1:
The patent divides the single machining line into multiple parallel machining lines (first machining line, second machining line, etc.), each handling different mask pieces simultaneously. This segmentation allows multiple masks to be processed in parallel, increasing overall productivity from 45-60 pieces/min to 300-400 pieces/min while keeping each individual machining line relatively simple.
Solution Approach 2:
The patent transitions from a single-line (one-dimensional) machining process to a multi-line (multi-dimensional) parallel processing system. By arranging multiple machining lines side by side and introducing staggered opposite arrangement of mask pieces, the system achieves dimensional expansion in the production process, enabling simultaneous processing of multiple masks at different stages.
2Loss of substance
If masks are arranged in a single line, then the device complexity is reduced, but material waste increases significantly
Solution Approach 1:
The patent employs asymmetric staggered opposite arrangement where mask pieces are positioned at different offsets on adjacent machining lines. The first mask piece on the first machining line is arranged differently from the second mask piece on the second machining line, creating an asymmetric pattern that optimizes material utilization and reduces wasted material around each mask.
Solution Approach 2:
The patent moves from one-dimensional linear arrangement to two-dimensional staggered opposite arrangement across multiple machining lines. By utilizing the lateral dimension and positioning mask pieces in a staggered pattern across different lines, the system achieves more efficient material coverage and reduces unused material while maintaining manageable device complexity.
3Loss of time
If multiple procedures are performed on one conveying line, then the device complexity is reduced, but the loss of time increases due to repeated operations
Solution Approach 1:
The patent segments the conveying and processing functions across multiple parallel conveying lines, allowing different mask pieces to undergo different procedures simultaneously. Instead of one line repeatedly performing edge folding, pressing, and cutting on the same mask multiple times, different lines handle different masks at different processing stages, reducing the time each mask spends in the system.
Solution Approach 2:
The patent implements preliminary actions where certain processing steps are performed in advance on specific mask pieces before they reach the main assembly area. For example, edge folding and pressing are performed on some mask pieces while other mask pieces are being prepared, allowing parallel execution of operations that would otherwise be sequential, thereby reducing total processing time.
Data Source
AI summary
A duckbill mask includes a mask upper side and a mask lower side. A manufacturing process includes: respectively performing edge folding and press sealing on an upper nose edge on the mask upper side and a jaw edge on the mask lower side, and using a double-way staggered cutting process to add a nose bridge while folding the upper nose edge; and overlapping the mask upper side and the mask lower side, then performing press sealing on convex edges of the mask upper side and the mask lower side by using a staggered opposite arrangement method, and using a double-way staggered cutting process to add an ear belt while performing press sealing on the convex edges. In the multi-line machining process, multi-line edge folding and press sealing of all layers of materials, overlapping and then finished product cutting are performed, whereby two duckbill masks are manufactured at a time.