Pre-cut Nose Wire Dispensing for High-Speed Mask Production

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Solution Overview

Problem

Current facemask production lines are limited in capacity, capable of producing only about 100 masks per minute, far short of the estimated 1,500 masks per minute needed during pandemics, due to the time-consuming process of cutting and placing nose wires, which also requires stopping the production line for splicing reserve wires.

Innovation Solution

A method and system for pre-cutting nose wires to a desired length and using a dispenser to meter and deposit them onto a running carrier web at defined spacing and orientation, eliminating the need for cutting and splicing, thereby increasing production efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If nose wires are cut and placed in-line during production, then manufacturing precision is maintained, but productivity is limited to 100 masks per minute

Engineering Contradiction:

Improvemask production rateVSAvoidtime for cutting and placing nose wires

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

Nose wires are pre-cut to desired lengths before the production process begins. The pre-cut nose wires are then supplied to a dispenser that meters and deposits them onto the running carrier web, eliminating the need for in-line cutting operations and significantly reducing the time required for nose wire placement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cutting operation is extracted from the in-line production process and performed separately beforehand. This separates the cutting function from the assembly line, allowing the production line to operate continuously without stopping for cutting operations, thereby increasing overall productivity.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If reserve nose wires are spliced onto the running wire, then continuity is maintained, but the production line must stop

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidproduction line speed

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

Multiple nose wires are pre-cut and loaded into the dispenser in advance. This preliminary preparation ensures that the dispenser always has nose wires available, eliminating the need for splicing operations and allowing the production line to maintain continuous operation at full speed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dispenser is designed to automatically feed pre-cut nose wires onto the carrier web without interruption. This continuous feeding mechanism eliminates stoppages for splicing reserve wires, maintaining both production line speed and productivity throughout the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS10786020B2Method and system for placing pre-cut nose wires in a facemask manufacturing process

Publication Date: 2020.09.29 O&M HALYARD INC

AI summary

A method and system are provided for placing nose wires in a facemask production line. A supply of individual pre-cut nose wires are supplied to a dispenser in the production line. With the dispenser, the nose wires are metered at a defined spacing and orientation onto a running carrier web that is conveyed past the dispenser. The carrier web and nose wires deposited thereon are conveyed to a folding station wherein a binder web is folded over an edge of the carrier web such that the nose wires are encapsulated between the binder web and the carrier web.