Z-Folded Web Stack with Mechanical Connectors for Dispenser Refill
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Solution Overview
Problem
Conventional refill procedures for web material dispensers are time-consuming due to the need for unwrapping and manual adhesion of multiple stacks, which can be heavy and difficult to handle.
Innovation Solution
A stack of web material with mechanical connectors on its end surfaces, allowing for secure interconnection with other stacks independently of orientation, facilitating easier handling and loading into dispensers without requiring precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive tape or glue is applied to the outer panels of the stacks for connection, then the stacks can be adhered together to form a compound stack, but the refill procedure becomes time-consuming and requires manual adhesion operations
Solution Approach 1:
The patent replaces the adhesive bonding system (chemical method) with a mechanical connector system. The mechanical connectors engage through interlocking structures that provide strong connections without requiring adhesive application, thereby eliminating the time-consuming manual adhesion operations while maintaining connection strength.
Solution Approach 2:
The mechanical connectors are designed to self-align and self-connect when stacks are placed together. The connector structures automatically engage through their geometric design, eliminating the need for manual positioning or adhesive application, thus reducing refill time while ensuring reliable connections.
2Ease of operation
If conventional packages are provided in sizes that are not too heavy and easily gripped, then the integrity of the stack can be maintained manually, but multiple stacks must be handled separately requiring repeated unwrapping and adhesion operations
Solution Approach 1:
The patent merges multiple stacks into a single compound stack through mechanical connectors. Instead of handling multiple separate packages that require individual unwrapping and adhesion, the connectors allow stacks to be joined into one integrated unit, improving productivity by reducing the number of handling operations while maintaining ease of operation through the unified structure.
Solution Approach 2:
The mechanical connectors are pre-installed on the stacks during manufacturing, enabling immediate connection without requiring unwrapping or additional preparation steps. This preliminary preparation of connection interfaces allows for faster refill operations while maintaining easy handling of the pre-assembled compound stack.
3Strength
If stacks are adhered via end panels with adhesive, then connection between stacks is achieved, but precise alignment and orientation control are required during refilling
Solution Approach 1:
The mechanical connectors employ asymmetric geometries that provide built-in alignment features. The connector structures are designed with specific orientations that guide proper positioning during assembly, eliminating the need for precise alignment operations. The asymmetric design ensures that connectors can only engage in the correct orientation, simplifying the refilling process while maintaining connection reliability.
4Quantity of substance
If multiple separate stacks are handled and adhered individually, then the dispenser can be refilled, but the process becomes heavy and difficult for the attendant to perform
Solution Approach 1:
The patent combines multiple stacks into a single compound stack using mechanical connectors, allowing the attendant to handle one integrated unit rather than multiple separate stacks. This merging reduces the number of handling operations and distributes the weight across a unified structure, making the refilling process less physically demanding while maintaining adequate web material supply.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The present disclosure relates to a stack (1) of web material for hygiene products, for use in a dispenser, comprising at least one continuous web material (2, 3) being Z-folded about transverse folding lines (4), thereby providing panels having a length (L) along said folding lines, and a width (W) perpendicular to said folding lines, said panels being piled on top of each other to form a height (H) of said stack extending between a first end surface (5) and a second end surface (6) of said stack 1, and said first end surface (5) being provided with a first connector (11a), and said second end surface (6) being provided with a second connector (11b). At least one of said first and second connectors (11a, 11b) comprises a first mechanical connector structure (51) and a second mechanical connector structure (52), said first and second mechanical connector structures (51, 52) being two corresponding structures, each structure being capable of forming a mechanical interconnection with said other structure, and being incapable of forming a mechanical interconnection with an identical structure, whereby said at least one of said first and second connectors (11a, 11b) is mechanically connectable to another connector of another stack of web material, said another connector comprising said first and/or second mechanical connector structure.