Reclosable Bag Zipper Audible Feedback Cutting Wheel
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Solution Overview
Problem
Existing methods for creating audible and tactile feedback in reclosable plastic zippers require additional manufacturing steps by separating and re-interlocking zipper halves, which is inefficient and increases machinery complexity.
Innovation Solution
A cutting wheel with rotating teeth, journaled on a common shaft and guided by linear bearings, applies pressure to interlocked zipper profiles, creating crescent-shaped impressions that produce tactile and audible feedback without separating the zipper halves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zipper halves are separated and re-interlocked to create deformations for audible feedback, then tactile and audible feedback is improved, but manufacturing complexity and time increase
Solution Approach 1:
The cutting wheel creates deformations in the zipper profiles while they are still interlocked during the manufacturing process, rather than requiring separation and re-interlocking steps. This preliminary action of creating the clicker impressions during the initial interlocking phase eliminates subsequent manufacturing steps and reduces overall process complexity.
Solution Approach 2:
The patent combines the deformation creation step with the zipper interlocking operation. The cutting wheel and pressure roller work simultaneously on interlocked profiles to create the necessary deformations, merging what were previously separate operations (interlocking and deformation creation) into a single integrated process.
2Reliability
If zipper halves are separated and re-interlocked to create deformations, then audible feedback is improved, but manufacturing time and efficiency decrease
Solution Approach 1:
The cutting wheel creates the necessary deformations in the zipper profiles during the initial interlocking operation, performing the deformation creation action preliminarily before any separation would occur. This eliminates the need for subsequent separation and re-interlocking steps, directly improving manufacturing efficiency while maintaining the audible feedback quality.
Solution Approach 2:
The manufacturing process maintains continuous operation with the cutting wheel and pressure roller working simultaneously on the interlocked profiles throughout the manufacturing cycle. This continuous action eliminates interruptions caused by separation and re-interlocking operations, thereby improving productivity while ensuring consistent audible feedback quality.
3Reliability
If additional manufacturing steps are added to create deformations, then tactile feedback is improved, but machinery complexity increases
Solution Approach 1:
The patent merges the deformation creation function into the existing interlocking machinery by using a cutting wheel and pressure roller that operate on the interlocked profiles. This integration eliminates the need for separate deformation creation equipment and steps, reducing machinery complexity while maintaining improved tactile feedback through the created deformations.
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
This method enhances manufacturing efficiency, increases tactile and audible feedback by distorting both male and female profiles, and reduces machinery modification needs, allowing for the production of zippers with enhanced feedback without the need for extra manufacturing steps.
Implementation Method 1
A pressure roller is applied from the male side of the material while the cutting wheel is applied on the female side of the material, or vice versa. The clicker impression wheels are applied toward the pressure roller, trapping the interlocked profiles/zippers in between the pressure roller and the clicker/impression wheels, thereby creating a visual pattern on the zipper
Implementation Method 2
a cutting wheel for cutting clicker impressions, wherein the cutting wheel is journaled for rotation by roller bearings on a common shaft
Data Source
AI summary
The present disclosure relates to an apparatus for manufacturing a reclosure for a reclosable package or container, such as a plastic bag, wherein opening or closing the zipper causes an audible sound and a tactile feel. The apparatus includes a cutting wheel which is opposed to a pressure wheel. The cutting wheel includes cutting teeth spaced about its periphery. Interlocked zipper material is engaged between the cutting wheel and the pressure wheel to form indentations in the interlocked zipper, thereby resulting in audible and tactile feedback when the zipper is operated.