Zig-Zag Folded Web Perforation Layout for Variable Sheet Lengths

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Solution Overview

Problem

Current tissue/towel folding equipment lacks flexibility in forming sheets of varying lengths and is inefficient in reducing shipping and storage space due to hollow central cavities in rolled products.

Innovation Solution

A folding apparatus that forms zig-zag folded logs of web material, utilizing a sheet delimiting apparatus to create adjustable weakened regions and a weakened region breaker to separate lengths of web material, allowing for customizable sheet lengths and minimizing wasted space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional folding equipment with fixed diameter processing rolls is used, then the machine structure is simple and reliable, but the flexibility to form sheets of different lengths is limited

Engineering Contradiction:

Improveflexibility to form different sheet lengthsVSAvoidmachine structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs dynamic adjustment mechanisms including variable speed drives on processing rolls, adjustable positioning systems for folding elements, and programmable control systems that allow the same machine to adapt to different sheet lengths by changing operational parameters rather than physical components

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes key operational parameters such as roll speeds, folding positions, and cutting points to accommodate different sheet lengths. The control system adjusts these parameters based on the desired output, allowing one machine to produce multiple sheet length specifications without structural modification

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If rolled product with hollow central cavity is used, then the product is easy to manufacture and handle, but significant shipping and storage space is wasted

Engineering Contradiction:

Improveproduct manufacturing easeVSAvoidshipping and storage space efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent segments the continuous rolled product into individual folded sheets or compact bundles. By folding the web material into zig-zag patterns and forming compact logs, the product is divided into space-efficient units that eliminate the hollow central cavity waste while maintaining ease of handling and manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates nested structures where folded sheets are arranged in compact logs with one sheet nested within another. The zig-zag folding pattern allows sheets to interlock and nest efficiently, maximizing space utilization in shipping containers and storage areas while eliminating the empty space characteristic of traditional rolls

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12570019B2Zig zag folder with perforator and zig zag folded web having perforations

Publication Date: 2026.03.10 C G BRETTING MFG CO INC

AI summary

An apparatus and method for forming zig-zag folded logs of web material is provided. The apparatus and method allows for forming logs having different sheet lengths on a same machine. Logs of web material having weakened regions at different locations between folds in the zig-zag folded web are also provided.