Paper Folding Unit With Selective Vacuum Holding Above 300 m/min

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Solution Overview

Problem

Existing folding and interfolding machines face limitations in speed and reliability due to mechanical and pneumatic systems that are complex, expensive, and require frequent maintenance, leading to inaccurate folds and machine jams at high speeds.

Innovation Solution

A folding or interfolding unit with mechanical gripping members and suction holes, utilizing a cam device for precise control and a vacuum distribution system to securely hold and release sheets at high speeds, eliminating the need for wedges and complex electronic circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical pliers with wedges are used to hold and introduce sheets, then the sheets can be securely gripped and folded, but the system becomes complex, expensive, and unable to work at high speed due to synchronization issues and frequent wear

Engineering Contradiction:

Improvesheet holding reliabilityVSAvoidfolding speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the complex mechanical wedge system with a pneumatic suction system. Instead of using mechanical wedges to introduce sheets into pliers, the invention uses suction holes to create vacuum pressure that holds sheets against the rolling surface. This pneumatic system eliminates the synchronization problems and wear issues of mechanical wedges while enabling high-speed operation above 300 m/min.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention employs pneumatic principles by using suction holes connected to a vacuum source. The suction holes create negative pressure that securely holds sheets on the rolling surface at specific positions. This pneumatic holding mechanism replaces the mechanical pliers and wedges, allowing for reliable sheet control at high speeds without the synchronization and wear problems of mechanical systems.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of manufacture

If mechanical pliers and wedges are used for sheet handling, then folding can be performed, but the devices require frequent maintenance due to wear and breaking of components

Engineering Contradiction:

Improvedevice simplicityVSAvoidmaintenance frequency

Core Design Contradiction:

Ease of manufactureVSEase of repair

Solution Approach 1:

The patent eliminates mechanical wear components by replacing the mechanical pliers and wedges with a pneumatic suction system. The suction holes and vacuum distribution device have no moving parts that subject to wear, dramatically reducing maintenance requirements. The system transitions from mechanical contact and friction to pneumatic field-based holding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If pneumatic suction systems with multiple rows of suction holes are used, then sheets can be held at determined portions, but the system requires complex vacuum distribution and cannot operate at high speed

Engineering Contradiction:

Improvefold accuracyVSAvoidfolding speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent divides the suction system into multiple independent suction holes arranged in rows at different angular positions. Each row of suction holes can be independently controlled by the vacuum distribution device to hold sheets at specific positions. This segmented approach allows precise control of sheet placement for accurate folding while the system can operate at high speeds above 300 m/min.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention makes the suction system dynamic by enabling the vacuum distribution device to selectively activate different rows of suction holes at different angular positions during rotation. This dynamic control allows the system to adapt to high-speed operation while maintaining precise sheet positioning for accurate folding, overcoming the limitation of static suction systems.

Inventive Principle:

Principle #15Dynamics

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 folding or interfolding of sheets exceeding 300 m/min with improved accuracy and reduced maintenance, ensuring consistent product quality and preventing jams.

Implementation Method 1

pneumatically connected to a device for generating a predetermined vacuum degree in such a way to cause the worked web, or sheet, to adhere only at determinate portions

Methodology Applied

Scientific EffectVacuum suction: Vacuum

Data Source

PatentUS12434937B2Folding or interfolding unit for folding or interfolding sheets of paper

Publication Date: 2025.10.07 KORBER TISSUE FOLD SRL

AI summary

A folding or interfolding unit includes first and second folding or interfolding rolls to fold or interfold the sheets of paper according to a predetermined folding or interfolding configuration. The first and second folding or interfolding rolls include, respectively, a tubular body configured to rotate in a predetermined direction of rotation about a longitudinal rotation axis, and gripping groups, each of which includes a mechanical gripping member configured to move, at a gripping point, from an opening position to a closing position, which is arranged to mechanically hold the sheets up to a releasing point. Each gripping group includes at least one suction hole associated to each mechanical gripping member. A vacuum distribution device selectively pneumatically connects at least one suction hole at a time to a device for generating a predetermined vacuum degree, to cause the sheets of paper to adhere between starting and ending positions.