Vacuum Nose Wire Placement for High-Speed Mask Production
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Solution Overview
Problem
Current facemask production lines are unable to meet high demand during pandemics due to limitations in technology and equipment, specifically struggling to efficiently cut and place nose wires at the required speed for mass production.
Innovation Solution
A method and system for cutting and placing individual nose wires using a vacuum conveyor to ensure precise placement on a carrier web, which is then encapsulated between webs, allowing for high-speed production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cutting and placement equipment is used, then the manufacturing process is simple, but the production speed is limited to about 100 masks per minute
Solution Approach 1:
The system divides the continuous wire into individual nose wire segments at high speed using a rotating blade that cuts multiple wires simultaneously as they are fed from a spool, enabling the carrier web to move at higher speeds while maintaining proper nose wire placement
Solution Approach 2:
The patent replaces conventional mechanical placement mechanisms with a high-speed cutting and placement system that uses a rotating blade and synchronized feed mechanism to cut and place nose wires in-line at speeds matching the high-speed carrier web transport, achieving 1500 masks per minute production capacity
2Productivity
If the carrier web moves at high speed for mass production, then productivity increases, but the nose wires cannot be properly held and placed on the web
Solution Approach 1:
The system performs preliminary cutting of the continuous wire into individual nose wire segments before they reach the placement zone, using a rotating blade that synchronizes with the carrier web speed to ensure each nose wire is ready for precise placement at high speed
Solution Approach 2:
The system uses sensors to detect the position and spacing of nose wires on the high-speed carrier web, providing feedback to the cutting and placement mechanism to maintain precise placement accuracy even at 1500 masks per minute production speed
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 the high-speed cutting and placement of nose wires, ensuring proper placement and encapsulation, thereby enhancing the efficiency of facemask production lines to meet increased demand during emergencies.
Implementation Method 1
A first web is conveyed to a vacuum conveyor, and the individual nose wires from the cutting station are also conveyed to the vacuum conveyor such that the nose wires are drawn by vacuum against the first web at a defined spacing and placement
Data Source
AI summary
A method and associated system are provided for cutting and placing individual nose wires in a facemask production line. A continuous wire is supplied from a supply source to a cutting station in the facemask production line where the continuous wire is cut into individual nose wires having a defined length. A first web is conveyed to a vacuum conveyor, and the individual nose wires are deposited from the cutting station onto the vacuum conveyor such that the nose wires are drawn by vacuum against the first web at a defined spacing and orientation. With the vacuum conveyor, the first web and attached nose wires are conveyed to a folding station wherein the first web and nose wires are combined with a second web such that the nose wires are encapsulated between the first and second webs.