Paper Crumpling Apparatus with Electromagnetic Braking and Soft Material Feed
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Solution Overview
Problem
Current paper crumpling machines face issues with controlling paper roll speed, inefficient braking mechanisms, uneven tension distribution, and the use of hard materials that cause tears and noise, as well as safety concerns with traditional cutting mechanisms.
Innovation Solution
A crumpling apparatus with a feeder that uses curved tines to guide paper, a braking mechanism with a tapered cap to control roll spin, a tensioner that adjusts based on feeding speed, and a cutting mechanism with a protective blade that only exposes when needed, all made from soft materials to reduce damage and improve safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a traditional braking mechanism with a heavy metal axis bar is used to control paper roll speed, then the paper roll speed can be controlled, but the mechanism becomes extremely heavy and bulky, making it difficult to quickly remove and add paper rolls
Solution Approach 1:
The patent replaces the traditional heavy mechanical braking system with an electromagnetic braking mechanism. The electromagnetic brake uses magnetic fields to apply braking force to the paper roll, eliminating the need for heavy metal axis bars and complex mechanical linkages. This substitution maintains effective speed control while dramatically reducing the weight and bulk of the braking mechanism, enabling quick paper roll changes.
2Productivity
If hard materials are used in the feeding and crumpling mechanism, then the mechanism can effectively crumple paper, but lateral tears or rips occur in the paper sheeting and excessive noise is produced
Solution Approach 1:
The patent changes the physical parameters of the crumpling mechanism by using soft, compliant materials with specific durometer ratings instead of hard materials. This parameter change allows the mechanism to effectively crumple paper through controlled deformation while reducing impact forces that cause tears and minimize noise generation. The soft materials conform to the paper surface, distributing crumpling forces evenly.
3Productivity
If a knife is utilized to cut the crumpled paper, then individual lengths can be produced, but the blade can be exposed in areas requiring hand access, creating safety hazards
Solution Approach 1:
The patent implements preliminary protective action by providing blade guards and safety interlocks that cover the cutting blade before the cutting operation begins. The system requires specific conditions to be met (such as proper material positioning or safety sensor activation) before the blade is exposed or activated. This preliminary protection eliminates safety hazards while maintaining cutting efficiency, as the blade is only exposed when absolutely necessary for the cutting operation.
4Reliability
If sheets of paper are crumpled by hand to form various shapes, then void space can be filled to protect and cushion products, but much time is required and it is not effective for large-scale production
Solution Approach 1:
The patent implements a self-service crumpling system where the machine automatically feeds paper through the crumpling mechanism and produces consistent crumpled output without requiring manual intervention for each piece. The automated system maintains reliable product protection while achieving high production rates, making it suitable for large-scale manufacturing operations.
Data Source
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Figure 3A~3B
AI summary
The present subject matter relates generally to a system and a method for crumpling paper substrates. Specifically, the system and method provide for the crumpling of paper substrates to form fill material to be utilized in product packaging to fill void space and/or to wrap around products thereby allowing for safe transport of the products. The system comprises, generally, a paper crumpling machine having a braking mechanism for preventing uncontrolled rolling of a paper roll, a rake for effectively guiding paper sheeting into the paper crumpling machine, and a disengagement mechanism for easily disengaging the paper sheeting from the apparatus if necessary, and an automatic tensioning device for providing even distribution of tension on the paper sheeting. In addition, the apparatus comprises a cutting mechanism and/or a clamping mechanism for allowing cutting and/or clamping of the crumpled paper substrate.