Method and system for manufacturing facemasks in a production line
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Solution Overview
Problem
Current facemask production lines are unable to meet the high demand for masks during pandemics due to technology and equipment restraints, producing only about 100 facemasks per minute, which is far short of the estimated 1,500 per minute needed, necessitating advancements in manufacturing processes for 'on-demand' production.
Innovation Solution
An automated method and system for manufacturing facemasks from a textile web involves conveying the web along a machine direction, attaching ties using ultrasonic bonding, and cutting the web and ties in the cross-machine direction to form facemasks at a rate of 200-700 facemasks per minute, utilizing a conveyor system with a rotating wheel and cutting drum for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual and automated methods are used to rotate rectangular bodies and attach ties, then facemasks can be manufactured, but production speed is relatively slow
Solution Approach 1:
Instead of rotating the rectangular bodies 90 degrees to attach ties along the left and right edges, the patent inverts the approach by keeping bodies oriented and attaching ties along the top and bottom edges. This eliminates the need for rotation mechanisms while achieving the same functional result of securing ties to the facemask bodies.
Solution Approach 2:
The patent extracts the rotation step from the manufacturing process entirely. By reconfiguring the tie attachment geometry to work with the body orientation as it comes off the pleating machine, the complex rotation mechanism is removed, simplifying the equipment while maintaining productivity.
2Productivity
If current production line technology is used, then facemasks can be manufactured, but throughput is limited to about 100 facemasks per minute
Solution Approach 1:
The patent applies preliminary action by pre-orienting the rectangular bodies in the correct position during the pleating process itself. The bodies are formed and positioned on the conveyor web with proper alignment before tie attachment occurs, eliminating the need for subsequent rotation operations and enabling higher throughput.
Solution Approach 2:
The patent ensures continuity of useful action by maintaining constant body orientation throughout the tie attachment process. Bodies move continuously along the conveyor in a fixed orientation, allowing tie attachment to occur without interruption or deceleration for rotation, thereby maximizing throughput to 200-700 facemasks per minute.
3Reliability
If stockpiles are maintained for emergency use, then aid workers and rescue personnel have protective facemasks available, but the stockpile must be continuously monitored for expiration and replenishing which is extremely expensive
Solution Approach 1:
The patent enables self-service through on-demand manufacturing capability. Production lines can be activated immediately when demand arises, eliminating the need for external monitoring and replenishment of stockpiles. The system serves itself by producing facemasks exactly when needed, converting a reactive stockpile management model into an active just-in-time production model.
Solution Approach 2:
The patent introduces dynamics into the supply chain by enabling flexible, on-demand production scaling. Manufacturing capacity can be dynamically adjusted based on real-time demand, allowing rapid response to emergencies without maintaining large static stockpiles. This dynamic production approach reduces the economic cost while maintaining reliability of supply.
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
The solution enables high-speed facemask production, significantly increasing throughput to 200-700 facemasks per minute, addressing the shortage by improving manufacturing efficiency and speed.
Implementation Method 1
attaching ties using ultrasonic bonding
Data Source
Figure 1
Figure 2A~2D
Figure 3
AI summary
An automated system (100) and method (200) for the manufacture of facemasks (70) from a web (12) of a textile product in a production line is provided. The web is conveyed in the production line along a machine direction (14). A first tie (26) is attached at a tie attaching station (54) to the web of the textile product, such that the first tie (26) extends from the web (12) in a cross-machine direction (22) perpendicular to the machine direction (14). The web (12) and first tie (26) are cut at a cutting station (58) in the cross-machine direction (22) across a width of the web (12) in the cross-machine direction (22) to form a facemask (70) separate from the web (12).