Automated Splicing Apparatus for Continuous Paperboard Corner Production

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

The manual process of changing paper rolls in paperboard corner manufacturing systems is hazardous and disrupts production, as operators must quickly cut and align paper sheets while maintaining production line speed.

Innovation Solution

A splicing apparatus that automates the process of aligning and joining the free ends of engaged and replenishing paper sheets with an adhesive tape, allowing for seamless integration without stopping the production line.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual roll changing is used, then device complexity is reduced, but operator safety deteriorates and production continuity is disrupted

Engineering Contradiction:
Improvesimplicity of roll changing mechanismVSAvoidoperator safety and production continuity
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The system performs self-service by automatically splicing paper rolls without operator intervention. The automated splicing device cuts the engaged roll, positions the replenishing roll, applies adhesive tape, and secures the connection while the production line continues operating, eliminating the need for manual roll changing and its associated safety risks and production disruptions

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical operation of roll changing with an automated mechanical splicing system. The automated device uses cutting mechanisms, positioning systems, adhesive tape applicators, and securing mechanisms to perform roll changes automatically, substituting human manual labor with automated mechanical processes that maintain production continuity

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If manual cutting and alignment is performed quickly, then production line speed is maintained, but operator injury risk increases

Engineering Contradiction:
Improveproduction line speedVSAvoidoperator injury risk from cutting tools
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The automated splicing device performs self-service by automatically cutting, aligning, and securing paper rolls without operator intervention. The device includes automated cutting mechanisms that precisely cut the engaged roll and replenishing roll, positioning systems that align the paper edges, and adhesive tape applicators that secure the connection, eliminating the need for operators to manually handle cutting tools and reducing injury risks while maintaining production speed

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent introduces an intermediary automated splicing device between the production line and the roll changing process. This intermediary system handles all dangerous operations (cutting, aligning, securing) automatically, acting as a mediator that protects operators from direct exposure to hazardous cutting tools while maintaining production continuity and speed

Inventive Principle:
Principle #24Intermediary (Mediator)

3Device complexity

If manual roll changing is used, then device complexity is reduced, but production continuity deteriorates

Engineering Contradiction:
Improvesimplicity of roll changing mechanismVSAvoidproduction continuity
Core Design Contradiction:
Device complexityVSProductivity

Solution Approach 1:

The automated splicing device enables continuity of useful action by performing roll changes during production line operation rather than stopping it. The device cuts the engaged roll, positions the replenishing roll, applies adhesive tape, and secures the connection while the production line continues to move paper products through the manufacturing process, eliminating interruptions and maintaining continuous production

Inventive Principle:
Principle #20Continuity of useful action

Solution Approach 2:

The system performs preliminary actions by pre-positioning the replenishing roll and pre-cutting the engaged roll before the actual splicing operation. The automated device prepares all necessary components (cutting the paper, positioning the replenishing roll) in advance, then executes the splicing operation without stopping production, ensuring continuous operation throughout the roll changing process

Inventive Principle:
Principle #10Preliminary action

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

The splicing apparatus ensures continuous production by automating the paper roll change process, reducing the risk of operator injury and enhancing operational efficiency.

Implementation Method 1

an adhesive tape applicator distinct from the engaged and replenishing sheet holders for applying an adhesive tape simultaneously to the aligned free engaged and replenishing paper ends such that the adhesive tape extends partially over the engaged paper sheet and partially over the replenishing paper sheet to join the free replenishing paper end to the free engaged paper end

Methodology Applied
Scientific EffectAdhesive: Adhesive

Data Source

PatentUS12269699B2Splicing apparatus and method for a paperboard protective corner manufacturing system
Publication Date: 2025.04.08 ABZAC CANADA INC
  • US12269699B2 patent drawing
  • US12269699B2 patent drawing
  • US12269699B2 patent drawing

AI summary

A splicing apparatus for splicing together an engaged paper sheet with a replenishing paper sheet in a paperboard corner manufacturing system, the apparatus comprising: an engaged sheet holder for holding the engaged paper sheet; an engaged sheet cutter for cutting the engaged paper sheet to form a free engaged paper end; a replenishing sheet holder for holding the replenishing paper sheet; a replenishing sheet cutter for cutting the replenishing paper sheet to form a free replenishing paper end; a sheet end alignment device for positioning both free engaged and replenishing paper ends relative to each other and substantially aligned with each other; an adhesive tape applicator for applying an adhesive tape simultaneously to the aligned free engaged and replenishing paper ends such that the adhesive tape extends partially over the engaged and replenishing paper sheets to join the free replenishing paper end to the free engaged paper end.