Method and apparatus for folding and opening-up wipes
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Solution Overview
Problem
Existing methods for producing wipes fail to efficiently transform flat materials into three-dimensional shapes, limiting the versatility and convenience of disposable absorbent products.
Innovation Solution
A method and apparatus that involve creating creases in a flat piece of material, folding it to form a planar blank, and then opening it into a three-dimensional shape, such as a cone, using counter-rotating drums and air pressure to facilitate the transformation and stacking of wipes for convenient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional flat wipe production methods are used, then manufacturing simplicity is maintained, but packaging efficiency and usability are limited
Solution Approach 1:
The method applies preliminary creasing and folding actions to the flat wipe material during the manufacturing process, transforming it into a pre-formed three-dimensional conical shape before packaging. This preliminary structuring enables more efficient stacking and packaging while maintaining a relatively simple manufacturing process using basic creasing and folding mechanisms.
Solution Approach 2:
The invention transitions the wipe from a two-dimensional flat shape to a three-dimensional conical form by introducing creases and folding the material along specific lines. This dimensional transformation allows the wipes to be stacked more efficiently in dispensers, improving packaging density and usability without requiring complex manufacturing equipment.
2Ease of operation
If flat wipes are used, then ease of manufacture is maintained, but dispensing convenience and usability are reduced
Solution Approach 1:
The three-dimensional conical shape is preliminarily formed during manufacturing through creasing and folding, so that the wipe is pre-prepared for optimal dispensing. This preliminary shaping allows the wipe to be easily accessed and dispensed from the container while maintaining manufacturing simplicity using basic folding mechanisms.
Solution Approach 2:
The invention employs curved folding patterns and creases that form a conical (spheroidal) shape from the flat material. This curved geometry naturally facilitates easier dispensing from containers as the rounded form allows smoother extraction and handling, while the curvature is achieved through simple creasing and folding rather than complex forming processes.
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 production of conical wipes that can be easily stacked and dispensed, enhancing the usability and packaging efficiency of disposable absorbent products.
Implementation Method 1
The blanks are then fed, one at a time, between the counter-rotating drums where friction and mechanical force transform each blank into a cone-shaped wipe
Implementation Method 2
opening it into a three-dimensional shape, such as a cone, using counter-rotating drums and air pressure to facilitate the transformation and stacking of wipes
Data Source
AI summary
Apparatus is provided for manufacturing a wipe in a three-dimensional form out of an essentially flat piece of material. The apparatus produces a blank of essentially flat planar form with a pleat folded on each side. The folded blanks are fed by a conveyor belt to an opening station. The opening station comprises a pair of movable pinch rollers which selectively grab individual blanks from the conveyor belt and feed them via belts to a pair of counter-rotating drums. The blanks are ejected from the drums, which partially opens them up in the process. The partially open blanks are fed onto a shaped former, where the final process of forming the wipe into its chosen three-dimensional form is completed.