Medical Patch Molding Line with Eye-Mark Recognition for Multiple Patch Types
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Solution Overview
Problem
Conventional dressing material molding apparatuses require significant time and cause defects due to deformation or twisting of fabric sheets, leading to decreased productivity and inability to accurately perform half-cutting or molding at precise positions, especially when characters are printed on the surface.
Innovation Solution
A method for molding medical patches using a medical patch molding apparatus that includes an eye-mark recognition process, a beveling process, and a complete cutting process, allowing different types of patches to be produced in a single process line by selectively performing these processes based on patch type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional molding apparatuses use a single device to mold different types of dressing materials with different sizes and shapes, then versatility is improved, but device complexity and operation time increase significantly
Solution Approach 1:
The molding apparatus is divided into multiple independent molding stations (first molding station, second molding station, third molding station), each equipped with dedicated molds for specific patch types. This segmentation allows each station to specialize in particular sizes and shapes, improving versatility without increasing the complexity of individual devices. The system can selectively activate different stations based on production requirements.
Solution Approach 2:
Each molding station is designed with universal capabilities to handle different patch types through standardized interfaces and interchangeable molds. The apparatus can mold various dressing patch sizes and shapes using the same basic infrastructure, achieving versatility without requiring a completely different device for each patch type.
2Adaptability or versatility
If conventional apparatuses replace different molds for different patch types, then adaptability is improved, but loss of time and productivity decrease
Solution Approach 1:
Multiple molds are pre-installed at different molding stations before production begins. Each station is configured with specific molds for particular patch types, eliminating the need for mold replacement during operation. The system prepares all necessary molds in advance at their respective stations, allowing immediate production without time-consuming changes.
Solution Approach 2:
The apparatus employs dynamic selection of molding stations based on the required patch type. Instead of statically replacing molds, the system dynamically activates the appropriate pre-configured station, enabling rapid adaptation to different production requirements without physical mold changes.
3Productivity
If fabric sheets are transported and processed through conventional apparatuses, then production capability is maintained, but deformation and twisting occur leading to defects
Solution Approach 1:
The apparatus replaces mechanical handling and positioning systems with a vision guidance system that uses cameras and image processing to detect fabric sheet positions and characteristics. This substitution eliminates mechanical deformation and twisting caused by physical handling, while maintaining high production capability through automated optical positioning.
Solution Approach 2:
The system incorporates real-time feedback through vision sensors that monitor fabric sheet position, orientation, and deformation during transport. This feedback is used to dynamically adjust processing parameters and positioning, ensuring accurate half-cutting and molding operations even when fabric sheets undergo minor variations during handling.
4Adaptability or versatility
If half-cutting and molding are performed on fabric sheets with printed characters, then product functionality is improved, but positioning accuracy deteriorates due to deformation
Solution Approach 1:
The vision guidance system replaces mechanical measurement and positioning methods with optical detection. Cameras capture images of printed characters on fabric sheets, and image processing algorithms precisely determine character positions and orientations without physical contact. This eliminates deformation-related positioning errors while maintaining the ability to process printed fabric sheets.
Solution Approach 2:
The system creates a digital copy (image) of the fabric sheet and its printed characters, then performs positioning and processing based on this digital representation rather than direct mechanical measurement. This copying approach allows precise position detection of printed characters without being affected by physical fabric deformation during handling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of various sizes of dressing patches with reduced defects and increased productivity by accurately performing half-cutting and molding operations, even when characters are printed on the fabric sheet.
Implementation Method 1
a heating unit, which heats the fabric sheet
Implementation Method 2
a cooling unit, which cools the fabric sheet molded in the molding unit
Data Source
AI summary
The present invention provides a method for molding medical patches using a medical patch molding apparatus including: a first process, which is an eye-mark recognition process for recognizing eye marks formed on the surface of a fabric sheet; a second process, which is a beveling process of compressing and thinning edges of a patch; and a third process, which is a complete cutting process of blanking a release sheet to form a handle part, wherein any one among the first to third processes is applied depending on the type of the patch, allowing different types of medical patches to be molded in a single process line.