Perforated Sheet Web Structure for Easy Tear and High-Speed Feeding
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Solution Overview
Problem
Conventional methods for manufacturing sheet products for dispensers face challenges in reducing the breaking force threshold of perforation lines while maintaining high machine feeding speed and throughput, leading to potential breakage during the manufacturing process and inconvenient user experience due to high friction in dispensers.
Innovation Solution
A method involving partially perforating the sheet web along a perforation line with alternating segments and non-cut segments, where the perforated segments have a smaller width and longer length than non-cut segments, allowing for increased breaking strength and reduced friction, enabling higher machine feed speeds and improved throughput without compromising yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If continuous perforation lines are used in conventional manufacturing, then the breaking force threshold is reduced for easier sheet detachment, but the web breaks during high-speed manufacturing processes
Solution Approach 1:
The continuous perforation line is segmented into alternating perforated segments and non-cut segments. This segmentation allows the web to maintain structural integrity during manufacturing while creating sufficient weak points for easy sheet detachment during dispenser operation.
Solution Approach 2:
Different segments of the perforation line have different properties: perforated segments provide easy detachment points, while non-cut segments maintain web strength during manufacturing. This local differentiation of properties resolves the contradiction between ease of operation and manufacturing reliability.
2Productivity
If high machine feeding speed is used to increase productivity, then throughput is improved, but the web breaks at perforation lines due to excessive tension
Solution Approach 1:
By segmenting the perforation line into perforated and non-cut segments, the web maintains sufficient strength during high-speed feeding while still allowing for easy sheet detachment. The non-cut segments bear the tension loads during manufacturing.
Solution Approach 2:
The perforation parameters are changed from continuous to alternating segments, modifying the mechanical properties of the web to withstand high-speed manufacturing while maintaining ease of use.
3Ease of operation
If perforation depth is increased to reduce breaking force, then sheet detachment becomes easier, but the web strength during manufacturing is compromised
Solution Approach 1:
The perforation is segmented such that only certain segments are fully perforated to create easy detachment points, while other segments remain non-cut to maintain web strength. This avoids the need to increase overall perforation depth.
Solution Approach 2:
Different segments have different perforation depths: perforated segments have sufficient depth for easy detachment, while non-cut segments maintain full web strength. This local differentiation resolves the contradiction between ease of operation and web strength.
Data Source
AI summary
The invention relates to a method of manufacturing a web of sheet product, with a discontinuous perforation arrangement such that manufacture of a web of sheet product provides for an increase in the breaking strength of the web of sheet product while feeding the web in a machine direction, thereby reducing the risk of breaking and maintaining the yield and throughput of the production of the perforated web as an intermediate product, yet providing a low breaking force for individual strips produced from the web.