Passive Folding Apparatus for Flexible Film Wrappers
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Solution Overview
Problem
Traditional methods for folding flexible film wrappers around consumer products like paper towel or toilet tissue rolls result in wrinkles, undesirable film stretching, and reduced production speed due to limitations in folding structures and methods.
Innovation Solution
A passive folding apparatus with specifically designed passive folding members and surfaces that gradually change angle and width to support and guide the flaps from a first position away from the product to a second position adjacent the product, minimizing wrinkles and film stretching, and increasing production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional folding structure and methods are used, then folding can be achieved, but wrinkles occur in final folds
Solution Approach 1:
The patent employs curved folding surfaces instead of flat or angular surfaces to guide the film flaps through a smooth arc-shaped path. This curvature allows the film to bend gradually without creating sharp creases or wrinkles, as the rounded surface distributes the bending stress evenly across the film material during the folding process.
Solution Approach 2:
The folding apparatus uses movable folding members that can adjust their position and angle dynamically during operation. This dynamic adjustment allows the folding surfaces to adapt to variations in film thickness, tension, and speed, maintaining optimal folding conditions that prevent wrinkle formation while accommodating real-time process variations.
2Manufacturing precision
If traditional folding structure and methods are used, then folding can be achieved, but undesirable film stretching occurs
Solution Approach 1:
The curved folding surfaces guide the film through a gradual arc-shaped path rather than forcing sharp bends. This curvature distributes the deformation evenly along the film, preventing localized stretching and maintaining the film's original dimensions and integrity throughout the folding process.
Solution Approach 2:
The patent modifies the geometric parameters of the folding surfaces, using optimized radii and angles that match the film's mechanical properties. By carefully selecting the curvature radius and folding angle parameters, the system minimizes stress concentration points that would otherwise cause film stretching while still achieving complete flap folding.
3Manufacturing precision
If traditional folding structure and methods are used, then folding can be achieved, but production speed is reduced
Solution Approach 1:
The folding members are designed to move synchronously with the film web speed, allowing continuous folding operation without interruption. The dynamic adjustment capability enables the system to maintain optimal folding velocity matching the production line speed, eliminating idle time and bottlenecks that reduce overall production throughput.
Solution Approach 2:
The folding apparatus is designed to operate continuously without stopping or resetting between folds. The movable folding members maintain constant contact with the film flaps throughout their travel, ensuring uninterrupted folding action that keeps pace with the continuous film web movement, thereby maximizing production speed and efficiency.
Data Source
AI summary
A folding apparatus is provided to be positioned adjacent a conveyor along which product having a flexible film wrapper wrapped about the product moves adjacent the folding apparatus such that the folding apparatus effects the folding of a first flap of the wrapper. The folding apparatus comprises a passive folding device comprising a first passive folding member defining a first passive folding surface adapted to engage the first flap as the product and the film wrapper move in a machine direction and folding the first flap from a first position away from the product to a second position adjacent the product.