Method and system for wrapping ties in a facemask manufacturing process
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Solution Overview
Problem
Current facemask production lines are unable to meet high demand during pandemics due to slow manual and automated methods for wrapping head fastening ties around facemasks, limiting throughput to around 100 masks per minute, which is insufficient for mass production needs of up to 1,500 masks per minute.
Innovation Solution
An automated method and system for wrapping fastening ties around facemasks in a production line, utilizing a conveyor system with suction devices, mechanical blades, or pneumatic devices to flip the facemasks and direct ties to wrap under the body, allowing for high-speed wrapping and compact packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or traditional automated methods are used for wrapping ties, then wrapping can be completed, but production speed is limited to around 100 masks per minute
Solution Approach 1:
The wrapping process is divided into distinct stages: initial tie positioning, first wrap around the mask body, and second wrap to complete the enclosure. Each stage is handled by specialized components working in sequence, enabling high-speed continuous processing without compromising wrapping quality
Solution Approach 2:
The system employs dynamic adjustment mechanisms that adapt to variations in mask size, tie length, and positioning. The wrapping components can rapidly adjust their positions and motions to accommodate different mask specifications while maintaining consistent wrapping tension and geometry
Solution Approach 3:
The wrapping process operates continuously without interruption between masks. The system maintains constant motion of wrapping components, with each mask being processed in an unbroken sequence from initial positioning through complete wrapping, eliminating idle time between units
2Productivity
If high-speed automated wrapping is implemented, then production throughput increases to 1,500 masks per minute, but device complexity increases
Solution Approach 1:
The wrapping system is designed with multi-functional components that can handle various mask types and sizes using the same basic mechanism. The apparatus can wrap different configurations of masks (surgical, N95, etc.) and tie arrangements through programmable control, reducing the need for multiple specialized devices
Solution Approach 2:
The system replaces complex mechanical wrapping mechanisms with a combination of pneumatic actuators, robotic positioning, and computer-controlled motion systems. This substitution enables more precise and rapid wrapping actions while simplifying the overall control architecture through digital programming
3Volume of moving object
If ties are left unwrapped, then packaging space is larger, but storage efficiency decreases and shelf life monitoring becomes more difficult
Solution Approach 1:
The wrapping process nests the ties within the mask body structure, with ties passing through and around the mask in an organized manner. This nested configuration allows masks to be stacked and packaged in compact arrangements, maximizing storage density in both horizontal and vertical dimensions
Solution Approach 2:
The wrapping utilizes the mask body's own structure as a flexible container, with ties being routed through and around the pleated body. This creates a self-contained package where the mask structure itself serves as the wrapping medium, eliminating the need for additional packaging materials while achieving compact form
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 high-speed wrapping of ties around facemasks, increasing production throughput and allowing for more compact packaging, thereby addressing the need for rapid facemask production during emergencies.
Implementation Method 1
The leading pair of ties are drawn below the body as the facemask continues to be conveyed
Implementation Method 2
an impinging force is directed against the body that causes the body to flip
Data Source
AI summary
An automated system and method wrap the fastening ties around the body of a continuous stream of facemasks in a facemask production line. The facemasks are oriented such that each facemask has a leading pair of ties and a trailing pair of ties extending from a body in a conveying direction of the production line. The leading pair of ties is drawn below the body as the facemask continues to be conveyed in the conveying. The body is conveyed through a plurality of conveyor sections oriented at angles such that the conveying direction of the body changes at a junction from one conveyor section to an adjacent conveyor section. At the junctions between conveyor sections, an impinging force is directed against the body that causes the body to flip, thereby causing the leading and trailing pairs of ties to further wrap around the body.