MACHINE CONFIGURED TO PRODUCE STACKS OF FOLDED WIPES

TECHNICAL FIELD

The present invention relates to a machine configured to produce stacks of folded wipes.

BACKGROUND

The term wipes generally refer to dispensable articles used to clean objects. Typical applications are human hygiene, household cleaning and medical applications, e.g., for disinfecting surfaces.

Wipes may be made from a variety of materials, which can be dry or wet when used. Wipes are enclosed by packaging, such as a container or similar, and the wipes are typically stacked inside the container.

The stack may optionally be folded across/orthogonal to the length/path direction of the material or folded both in the length direction of the material and across/orthogonal to the length direction of the material. Various folding patterns such as a V-folded, Z-folded, or M-folded configuration is well known to those skilled in the art.

Wipes intended for use when wet, referred to as wet wipes, can be moistened with a variety of suitable solutions.

Wipes may further be configured for single handed, one at a time dispensing, often referred to as “pop-up” dispensing. In other words, when a user pulls one wipe from its packaging or container, the next wipe pops up and is readily available to grab when the user so desires. This form of stacking is particularly desirable for applications where a first hand of the user is typically required to be simultaneously used for other functions. Some conventional solutions use interfolded configuration to get pop-up functionality, with the wipes interfolded with other wipes in the stack immediately above and immediately below.

Stacks of wipes are typically produced by a machine that uses material, typically tissue/fabric, placed on a roll and produces a stack of wipes in a desired format.

Some conventional solutions produce stacks of wipes folded in one direction, interfolded, or not interfolded, by subjecting the material to different operations in separate material paths, one path for each wipe in a stack. Examples of such operations are folding in the length direction of the material, moisturizing the material with a suitable solution, putting each lane on top of the stack that is being made, if needed creating the interfold, and finally cutting the complete stack in the required length. An example of a machine having separate material paths is shown in U.S. Pat. No. 8,097,326B2.

Drawbacks of this type of conventional solutions include a large footprint required to house the machine and that a large number of components need to be replaced when reconfiguring the machine to produce different stack or wipe formats. In other words, changing the desired specifications of the stacks/wipes are generally a complex procedure, and typically requires substantial re-build and replacement of components in the machine. A further drawback is that producing stacks with relatively narrow width may result in ply buildup. A further drawback is that the number of wipes in a stack is limited by the number of material holders, as each wipe in a stack requires a separate material holder per material path.

Other Conventional solutions produce stacks of wipes folded in two directions (typically a direction in the machine/path/length direction and a width direction/direction orthogonal to the length direction) by subjecting the material to different operations in a single path or multiple single paths in parallel to increase capacity, the single path of material is subjected to operations such as: unrolling material, wetting material, longitudinal folding of material, cutting to individual wipes having a desired length, held in place with a vacuum or tape and folded in half with an inserter/infeed plate and gripper and then stacked. The pile will therefore inevitably consist of individual napkins that cannot be interfolded to provide pop up functionality. An example is show in document US2003172821A1.

Drawbacks of this type of conventional solutions include inflexibility and restriction in supported formats. In other words, changing the desired specifications of the stacks/wipes are generally a complex procedure, and typically requires substantial re-build and replacement of components in the machine.

A further drawback with conventional solutions is that different machines are used to produce wipes for folding in a single or to produce wipes for folding in multiple directions.

Yet another drawback with conventional solutions using perforations between wipes, is that perforations used are generally strong and are designed to maintain sufficient strength/structural integrity in the material to process the material or wipes.

Thus, there is a need for an improved machine to produce stacks of folded wipes.

OBJECTS OF THE INVENTION

An objective of embodiments of the present invention is to provide a solution which mitigates or solves the drawbacks described above.

SUMMARY

The above objective is achieved by the subject matter described herein. Further advantageous implementation forms of the invention are described herein.

According to a first aspect of the invention the object of the invention is achieved by a machine configured to produce stacks of folded pop-up wipes from material. The material is threaded along a path having a direction through the machine comprising a holder of the material, a first tension unit, a perforation unit configured to generate a perforation in the material in a direction orthogonal to the direction of the path, a folding unit configured to fold the material in a direction orthogonal to the direction of the path, a control unit communicatively coupled to at least the first tension unit, the perforation unit and the folding unit, wherein the material is threaded along a path through the machine via at least the first tension unit, the perforation unit and the folding unit, wherein the control unit is configured to control the machine to produce folded pop-up wipes by individually controlling tension of material along one or more sections of the path. The control unit is further configured to control the machine to increase tension of the material in a section of the path located after the perforation unit to stretch a generated perforation in the section of the path by a target distance.

In one embodiment, the produced stacks of folded pop-up wipes comprise a continuous web.

In one embodiment, the section of the path is located between the first tension unit and the folding unit.

In one embodiment, the control unit is further configured to control the machine to increase tension of the material in a section of the path to separate the material at a generated perforation.

In one embodiment, the section of the path is located between the first tension unit and the folding unit.

In one embodiment, the material is separated into parts when the generated perforation is located after the perforation unit.

In one embodiment, the control unit is further configured to control the machine to adjust tension of the material in a section of the path located after the perforation unit and before the folding unit to adjust the relative location of a perforation generated by the perforation unit in a produced stack of folded pop-up wipes.

In one embodiment, the control unit is further configured to control the machine to adjust relative distance between perforations generated by the perforation unit to adjust the relative location of a perforation generated by the perforation unit in a produced stack of folded pop-up wipes.

The advantage of this first aspect includes at least that complexity is reduced when reconfiguring the machine to a desired stack format or wipe format. A further advantage is that single direction folded pop-up wipes and multiple direction folded pop-up wipes can be produced in the same machine. A further advantage is that the footprint of the machine is reduced. A further advantage is that multiple wipe formats can be combined in one stack, e.g., a care pack.

In other words, multiple wipe formats in a continuous web separated by perforations may be produced.

According to a second aspect of the invention the object of the invention is achieved by a method performed by the machine according to the first aspect configured to produce stacks of folded pop-up wipes from material, the method comprising controlling the machine to produce folded pop-up wipes by individually controlling tension of material along one or more sections of the path.

In one embodiment, the method further comprises controlling the machine to increase tension of the material in a section of the path located after the perforation unit to stretch a generated perforation in the section of the path by a target distance.

In one embodiment, the section of the path is located between the first tension unit and the folding unit.

In one embodiment, the method further comprises controlling the machine to increase tension of the material in a section of the path to separate the material at a generated perforation.

In one embodiment, the section of the path is located between the first tension unit and the folding unit.

In one embodiment, the material is separated into parts when the generated perforation is located after the perforation unit.

In one embodiment, the method further comprises controlling the machine to adjust tension of the material in a section of the path located after the perforation unit and before the folding unit to adjust the relative location of a perforation generated by the perforation unit in a produced stack of folded pop-up wipes.

According to a third aspect of the invention the object of the invention is achieved by a computer program product comprising instructions which, when the program is executed by a computer, cause the computer to carry out the method according to the second aspect.

According to a third aspect of the invention the object of the invention is achieved by a computer-readable storage medium comprising instructions which, when executed by a control unit, cause the control unit to carry out the steps of the method according to the second aspect.

The scope of the invention is defined by the claims, which are incorporated into this section by reference. Reference will be made to the appended sheets of drawings that will first be described briefly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a machine according to one or more embodiments of the present disclosure.

FIG. 2 shows the control unit communicatively coupled to other units according to one or more embodiments of the present disclosure.

FIG. 3A shows a perforation before adaption according to one or more embodiments of the present disclosure.

FIG. 3B shows a perforation after adaption according to one or more embodiments of the present disclosure.

FIG. 4A shows a perforation before separation of wipes according to one or more embodiments of the present disclosure.

FIG. 4B shows a perforation after separation of wipes according to one or more embodiments of the present disclosure.

FIG. 5A shows a side view of a stack of folded wipes according to one or more embodiments of the present disclosure.

FIG. 5B shows a top view of a stack of folded wipes according to one or more embodiments of the present disclosure.

FIG. 6 shows a path of material threaded through the machine according to one or more embodiments of the present disclosure.

FIG. 7A shows an example of a section of the path according to one or more embodiments of the present disclosure.

FIG. 7B shows a further example of a section of the path according to one or more embodiments of the present disclosure.

FIG. 8 illustrates details of a folding unit according to one or more embodiments of the present disclosure.

FIG. 9 shows the control unit according to one or more embodiments of the present disclosure.

FIG. 10 shows a flowchart of a method according to one or more embodiments of the present disclosure.

FIG. 11A illustrates a V-folding pattern.

FIG. 11B illustrates a Z-folding pattern.

FIG. 11C illustrates a M-folding pattern.

FIG. 12 illustrates a stack comprising wipes having multiple formats.

A more complete understanding of embodiments of the invention will be afforded to those skilled in the art, as well as a realization of additional advantages thereof, by a consideration of the following detailed description of one or more embodiments. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.

DETAILED DESCRIPTION

Generally, all terms used herein are to be interpreted according to their ordinary meaning in the relevant technical field, unless a different meaning is clearly given and/or is implied from the context in which it is used. All references to a/an/the element, apparatus, component, means, step, etc. are to be interpreted openly as referring to at least one instance of the element, apparatus, component, means, step, etc., unless explicitly stated otherwise. The steps of any methods disclosed herein do not have to be performed in the exact order disclosed, unless a step is explicitly described as following or preceding another step and/or where it is implicit that a step must follow or precede another step. Any feature of any of the embodiments disclosed herein may be applied to any other embodiment, wherever appropriate. Likewise, any advantage of any of the embodiments may apply to any other embodiments, and vice versa. Other objectives, features and advantages of the enclosed embodiments will be apparent from the following description.

An “or” in this description and the corresponding claims is to be understood as a mathematical OR which covers “and” and “or”, and is not to be understand as an XOR (exclusive OR). The indefinite article “a” in this disclosure and claims is not limited to “one” and can also be understood as “one or more”, i.e., plural.

In the present disclosure the term “wipe” denotes dispensable articles used to clean objects. More specifically a dispensable cloth for use in a dry or wet condition.

The wipe is made from a suitable material, such as a fabric, web, weave, tissue, material, or woof depending on the application. Typical applications are human hygiene, household cleaning and medical applications, e.g., for disinfecting surfaces. Wipes are enclosed by packaging, such as a container or similar, and the wipes are typically stacked inside the container. Alternatively, wipes are placed in the container in the form of a continuous web of material, such as a roll with or without perforations.

Such a continuous web of material using perforations to define the wipes may be placed in a container and form folded pop-up wipes. Wipes provided with pop-up functionality is referred to as pop-up wipes or simply wipes herein.

In the present disclosure the term “stack of folded wipes” denotes a plurality of wipes placed on top of each other in an aligned manner.

In particular, the present disclosure relates to stacks of folded wipes comprising continuous material, such as a continuous web. The continuous material is separated into wipes by perforations, as further described in relation to FIG. 5 and FIG. 11A-C.

The stack may optionally be folded across/orthogonal to the length direction of the material or folded both in the length direction of the material and across/orthogonal to the length direction of the material. Various folding patterns such as a V-folded, Z-folded, or M-folded configuration as are well known to those skilled in the art.

FIG. 11A-C illustrates stacks of folded wipes comprising continuous material, such as a continuous web using perforations to delimit/define wipes in the stack. The continuous material can later be separated into wipes by a user by breaking the perforations, E.g., using a quick pulling motion.

In the present disclosure the term “path” denotes the way through which the material is threaded via different parts of a machine.

In the present disclosure, the terms “length direction”, “machine direction” and path direction are used interchangeably. The terms denote a direction in the material from the start of the material to the end of the material in a length direction, where the material has a rectangular shape with a length larger than the width. The material is threaded through the machine along a path and the length direction of the material aligns with the path direction of the material, at least in sections of the path. This definition is applied also after a wipe is separated from the material or roll of material.

In the present disclosure, the term “perforation unit” denotes a unit configured to place a perforation on the material, e.g., a jagged knife pressing the material against a roller or plate.

The present disclosure relates to a machine for producing wipes, such as pop-up wipes. In particular, a machine providing increased flexibility and reduced complexity when producing wipes, such as pop-up wipes, or stacks of different formats and/or with multiple folding directions.

The machines available today sometimes require a separate path of material through the machine for each wipe in a stack, and each path needs to be re-built to support production of wipes having a different format and/or a different folding pattern.

Also, in applications where a perforation is provided in the material to enable separation of wipes, conventional solutions typically provide such a strong perforation that a custom lid is required on the container, that assists with a counter force when the user is trying to tear off a wipe. This has the disadvantage of a more complex container and/or use of both hands. Further, popup functionality cannot be provided when using perforated configuration of the wipes without the use of a customized lid on the container to help with separating wipes. Popup functionality is typically provided also using interfolded configuration with folds in one direction of the material.

Alternatively, conventional solutions achieve a popup effect for the wipes by applying a single direction fold/interfold technique. However, this solution has the disadvantage that configurations having multiple folding directions are excluded.

The present disclosure overcomes the disadvantages above by providing a machine that can produce wipes and/or stacks with different formats and/or multiple folding directions using a single path of material, and is further able to produce them in the same machine.

The present disclosure achieves this by providing advanced individual control of units, e.g., units comprising rollers, in the machine, and a folding unit using grippers and infeed plates. This has at least the advantage of reducing complexity when changing production to stacks or wipes having a different format and/or folding pattern.

A further advantage is that single direction folded wipes and multiple direction folded wipes can be produced in the same machine.

A further advantage is that wipes and/or stacks using different format and/or folding pattern can be produced in the same stack of wipes. This is e.g., useful when producing a “care pack” with different wipes used in a cleaning operation. Such a care pack might include two short wipes not folded with a length equal to the width of the stack and two long wipes folded three times and with a length equal to four times the width of the stack.

The disclosed machine can provide popup functionality to wipes using perforations by adapting the strength or structural integrity of perforations provided to the wipes. Further the disclosed machine can provide popup functionality for folds in one or two directions of the material, I.e., popup functionality also for perforated material that is folded in both the length and the width direction of the material. This is achieved by individually controlling units in the machine. In particular, controlling actuators of the machine to stretch generated perforations to a desired target strength, e.g., a strength or structural integrity suitable to provide popup functional to the wipes.

This has the advantage of adapting perforations to a target/desired strength or structural integrity, which in turn allows generation of relatively weak perforation that can achieve popup solutions allowing one hand operation with a similar performance to interfold configuration solutions, but with the flexibility of using perforations and/or folding in single or multiple directions.

The disclosed machine can, as mentioned, produce pop-up wipes using different formats and/or folding patterns in the same stack of wipes. This is e.g., useful when producing a “care pack” with different wipes used in a cleaning operation. Such a care pack might in one example include two short wipes not folded with a length equal to the width of the stack and two long wipes folded three times and with a length equal to four times the width of the stack.

FIG. 1 shows a machine 100 according to one or more embodiments of the present disclosure. The machine 100 is configured to produce stacks of folded wipes 192 from material 110, e.g., fabric.

The machine optionally comprises a holder 111 configured to hold the material. In one example, the material 110 is rolled up on a roll, and the holder 111 is configured to hold the roll of material and rotate the roll of material at a target material velocity and/or target angular velocity. The material 110 typically has a rectangular form having a length, and an associated length direction from one end, along the length of the rectangular form to a second end, e.g., in the form of a sheet of fabric rolled onto the roll. The length direction is also referred to as path direction. The material 110 further has a width and a width direction across/orthogonal to the length direction of the material. The material 110 further has a thickness substantially smaller than the length and the width of the material 110.

The machine comprises at least a first tension unit 160, an optional perforation unit 170 and a folding unit 180.

The material or at least a section of the material 110 is threaded along a path 112 through the machine 100. The path is further described in relation to FIG. 6. The path runs via at least the first tension unit 160, the perforation unit 170 and the folding unit 180. In one example, the path may run through the first tension unit 160, then through the perforation unit 170 and finally via the folding unit 180. In a further example, the path may run through the perforation unit 170, then then through the first tension unit 160 and finally via the folding unit 180.

The first tension unit 160 is configured to adapt tension of the material 110 in a section of the path. In other words, as the path or material path 112 runs through the first tension unit 160 the tension of the material along a section 712 of the path 112 may be adapted to a desired target tension of the material.

In one example, the first tension unit 160 comprises two rollers between which the path of material pass between. The material may optionally be subjected to a particular force by the two rollers, resulting in a friction between the rollers and the material. At least one of the rollers is provided with a controllable actuator, such as a servo motor, by which rotational position and/or angular velocity and/or material velocity and/or force between rollers may be controlled.

The folding unit 180 is configured to receive the material 110, e.g., via an inlet, and fold the material in a width direction/cross direction/, i.e., in a direction across/orthogonal to the length direction of the material. In other words, the folding unit 180 folds the material in the width direction of the material. After folding of the material 110 by the folding unit 180, folded wipes 191 are formed, e.g., at an outlet. The material is folded in alternating directions effectively forming a zig-zag pattern, when seen from the side of the stack or in a direction orthogonal to the length direction of the material. This zig-zag pattern is further described in FIG. 5 and FIG. 11A-C. Optionally, the folded wipes 191 are separated every number N wipes and form stacks of folded wipes 192.

In other words, the continuous material, e.g. a continuous web, in the formed folded wipes 191 is separated at a perforation to form a stack comprising a number N wipes, where the N wipes are connected by perforations.

In one example, the folding unit 180 comprises two rollers between which the path of material passes between. Each roller alternatively grips and folds the material and form the folded wipes 191. The folding unit 180 is further described in relation to FIG. 8. As mentioned, the material is folded in alternating directions effectively forming a zig-zag pattern as further described in FIG. 5 and FIG. 11A-C.

Each of the rollers in the folding unit 180 are provided with controllable actuators, such as servo motors, by which any of rotational position, angular velocity, and material velocity may be controlled. Rotational position, angular velocity and distance between rollers are typically defined in relation to a length axis (not shown) of a respective roller. Rotational position defines positions of the roller when rotated around the length axis. Angular velocity defines rotational velocity of the roller when rotated around the length axis.

The machine 100 further comprises a control unit CU communicatively coupled to at least the first tension unit 160, the perforation unit 170 and the folding unit 180. The control unit CU is further described in relation to FIG. 2 and FIG. 9. The control unit CU is configured to control the machine 100 to produce folded wipes 191 and/or stacked folded wipes 192 by individually controlling tension of material 110 along one or more sections of the path. Examples of sections of paths are discussed further in relation to FIG. 7A and FIG. 7B.

In one example, the first tension unit 160, the perforation unit 170 and the folding unit 180 are provided with actuators, and the actuators are individually controlled by the control unit CU, e.g., controlling rotational position, material velocity, and angular velocity to individually control tension of material 110 along one or more sections of the path.

The machine 100 further optionally comprises a moisturizing unit 150 configured to moisturize or wet the material 110 with a suitable solution depending on the application. The moisturizing unit 150 may be communicatively coupled to and controlled by the control unit CU. The solution may be any solution which can be absorbed into the wipes, thus making them “wet wipes.” The wipes can in principle be moistened at any time before the wipes are actually used by the consumer. They can be moistened sometime during the manufacturing process before or contemporaneous with the plurality of wipes being sealed in a container, dispenser, or other packaging for next use by a user. The solution contained within the wet wipes can include any suitable components which provide the desired wiping properties. For example, the components can include water, disinfectant, emollients, surfactants, preservatives, chelating agents, pH buffers, fragrances, or combinations thereof. The solution can also contain lotions, ointments and/or medicaments. The machine 100 further optionally comprises a second folding unit 140 configured to receive the material 110 and fold the material in the length direction of the material. After folding of the material 110 by the second folding unit 140, the material is folded once or more times along the length direction of the material. This may include V-folded, Z-folded, or M-folded configuration in the length direction of the material, as are well known to those skilled in the art. Any other folding pattern known in the art may be considered. As mentioned previously, the material is folded in alternating directions effectively forming a zig-zag pattern as further described in FIG. 5 and FIG. 11A-C.

The machine 100 further optionally comprises a second tension unit 130 which is configured to adapt tension of the material path to a target tension. In other words, as the path or material path 112 runs through the second tension unit 130 the tension of the material in a section 712 of the path along the path 112 may be adapted to a desired target tension of the material.

In one example, the second tension unit 130 comprises two rollers between which the path of material pass between. At least one of the rollers is provided with controllable actuators, such as servo motors, by which rotational position and/or angular velocity may be controlled. By controlling the angular velocity and/or the material velocity, the tension in a section of the path 712 located before the second tension unit 130 may be adapted.

The machine 100 further optionally comprises a feed control unit 120 which is configured to measure tension of the material along a section of the path between the holder 111 and the feed control unit 120. The feed control unit 120 then sends a control signal to the control unit CU indicating the tension. The control unit CU then sends a control signal to the holder 111 indicative of a feed rate resulting in a desired tension of the material along the path between the holder 111 and the feed control unit 120. In other words, as the path or material path 112 runs through the feed control unit 120 the tension of the material along the path 112 is measured and used to control the material feed rate of the holder 111.

The machine 100 further optionally comprises a wipe stacking unit 190 configured to produce stacked folded pop-up wipes 192 from folded wipes 191. In other words, the wipe stacking unit 190 is configured to receive the folded wipes 191.

In one example, the path or material path is provided with multiple perforations, where sections of the material between the perforations form wipes. In other words, the wipes are coupled with perforations or strings of material remaining after perforation by the perforation unit 170 and then fed to the folding unit 180. The wipe stacking unit 190 receives the folded wipes still coupled with perforations and generates one or more stacks of folded wipes 192.

The wipe stacking unit 190 is further optionally configured to separate the folded wipes 191 every number N of wipes and forms stacks of folded wipes 192.

In one example, this may be performed by a mechanical arrangement capable of separating the material. E.g., a plate pushing on top of a wipe in the folded wipes 191 to separate a generated perforation and form a stack of folded wipes 192.

In one further example, this may further be performed by controlling the relative speed of the material through any of the units 110-170 located before the folding unit 180 and the relative speed of the material through the folding unit 180. The number N wipes can then be separated by breaking the perforation and separating the folded wipes 191 to forms stacks of folded wipes 192. This is further described in relation to FIGS. 4A and 4B.

Optionally, the stacks of folded wipes 192 are further transported to a packing unit configured to place each stack of folded wipes in a desired container or packaging.

It is understood that the order of the units 120-180 may vary without diverting from the present disclosure.

FIG. 2 shows the control unit CU communicatively coupled to other units according to one or more embodiments of the present disclosure. The control unit CU is configured to send or receive control signals to/from the units 120-190 described in relation to FIG. 1. In other words, the units 120-190 may send information to the control unit CU and receive information or commands from the control unit CU.

In one example, the control unit CU controls the tension in a section of the path 712 between the first tension unit 160 and the folding unit 180 by individually controlling rotational position and/or material velocity and/or angular velocity of rollers in the first tension unit 160 and the folding unit 180.

The control unit CU is further described in relation to FIG. 9.

In some aspects of the present disclosure the pulling force required to separate wipes is adapted, e.g., to provide a popup effect for material or wipes provided with perforations. The present disclosure further enables providing a popup effect for wipes folded in multiple directions, I.e., both the length direction and the width direction. This is differing the present disclosure from conventional solutions which have had to rely on interfold configurations, I.e., folding of the wipes in a single direction of the material/path.

In other words, by adapting the pulling force required to separate pop-up wipes also wipes folded multiple times can provide pop-up functionality. In conventional solutions, the force required to break a perforation is substantially doubled when the material is folded.

After generating a perforation in the material according to the present disclosure, the required breaking force of the perforation in a folded stack of wipes may be adapted by stretching the perforation.

FIG. 3A shows a perforation before adaption according to one or more embodiments of the present disclosure.

Typically, perforation unit 170 generates a perforation 310 in a direction across/orthogonal to the length direction of the material along the path 112. The generated perforation will have certain characteristics such as the force required to separate wipes on opposite sides of the perforation. In other words, the pulling force that is required to separate wipes and break the perforation.

These characteristics may differ from desired/target characteristics depending on the application of the wipes.

In one example, if a user of wet wipes, such as baby wipes, wishes to separate wipes using a quick pull resulting in a “pop-up”, the perforation characteristics must be adapted to ensure that the wipe can be separated without pulling several wipes out from the container.

In other words, when a user wants to dispense a wipe from a stack of wipes 192 comprising continuous material/web, it is desirable that he/she can do so with a quick pull without pulling several wipes from the stack.

The present disclosure solves this by configuring the machine to adapt the perforation characteristics to target perforation characteristics by stretching the generated perforation 310.

In one embodiment, the control unit CU is further configured to control the machine to increase tension of the material or fabric 110 in a section of the path 712 located after the perforation unit 170 to stretch a generated perforation 310 in the section of the path 712 by a target distance ΔS. The exact relation between the target distance ΔS and the adaption of pulling force required to separate wipes depends on the material used, and the relation may be determined using experiments and stored in memory of the control unit CU.

In one example, the control unit CU controls the tension in a section of the path 712 between the first tension unit 160 and the folding unit 180 e.g., by controlling rotational position and/or angular velocity of rollers in the respective unit. In other words, the material moves at different rates or velocity through the first tension unit 160 and the folding unit 180 thereby increasing the tension in a section of the path comprising the perforation. This may involve moving/rotating rollers in the first tension unit 160 relative to movement/rotation of rollers in the folding unit 180. This relative movement/rotation will increase tension in the material in the particular section of the path. As the perforation 310 is the weakest part of the material path 712, the majority of stretching of the material will occur in the section of the material provided with the perforation, and the perforation may be stretched the target distance ΔS.

FIG. 3B shows a perforation after adaption according to one or more embodiments of the present disclosure.

In FIG. 3B the perforation 310 shown in FIG. 3A is stretched by a target distance ΔS, thereby achieving desired/target characteristics of the perforation. In one example, the perforation is made weaker to allow for one-hand separation of a wipe from a stack of wipes and simultaneous partial exposure of the next wipe, so called popup effect. In other words, the pulling force required to separate wipes is adapted.

In some aspects of the present disclosure the machine is configured to separate folded wipes 191 to form stacks of folded wipes 192 using the folding unit 180. This further reduces the complexity of the machine 100, as no mechanical arrangement capable of separating the material is required.

In one example, the separation of folded wipes 191 is done just before rollers of the folding unit, which allows the rollers to grab hold of the loose end of the material and proceed to form another stack of folded wipes 192. In other words, the folded wipes 191 are separated every number N of wipes and forms stacks of folded wipes 192.

FIG. 4A shows a perforation 310 before separation of wipes according to one or more embodiments of the present disclosure.

Typically, the perforation unit 170 generates a perforation 310 in a direction across/orthogonal to the length direction of the material along the path 112. The generated perforation 310 will have certain characteristics such as the force required to separate wipes on opposite sides of the perforation. In other words, the pulling force required to separate wipes and break the perforation. The exact relation between the target distance ΔS required to separated wipes and a corresponding pulling force depends on the material used, and the relation may be determined using experiments.

In one embodiment, this knowledge of the pulling force and/or target distance ΔS required to separate wipes and break the perforation is used to separate folded wipes 191 to forms stacks of folded wipes 192.

In one example, the folding unit 180 separates a wipe that is about to be folded or is in the process to get folded. In other words, the folding unit 180 separates a first wipe close to or in its inlet, thereby allowing the second/next wipe to be fed into the folding unit 180, and then forms the first wipe in the next stack of folded wipes 192.

The present disclosure solves this by configuring the machine to separate a stack of folded wipes 192 from the folded wipes 191 by stretching the generated perforation 310 beyond a breaking point.

This has the advantage of reducing the complexity of the machine, as no separate arrangement is needed in the wipe stacking unit 190 to separate folded wipes 191 into stacks of folded wipes 192.

In one example, the control unit CU controls the tension in a section of the path 712 between the first tension unit 160 and the folding unit 180 e.g., by controlling rotational position and/or angular velocity of rollers in the respective unit. In other words, the material moves at different rates or velocity through the first tension unit 160 and the folding unit 180 thereby increasing the tension in a section of the path 712 comprising the perforation 310 until the perforation breaks and adjacent wipes are separated. This may involve moving/rotating rollers in the first tension unit 160 relative to movement/rotation of rollers in the folding unit 180. This relative movement/rotation will increase tension in the material in the particular section of the path 712 provided with the perforation 310. As the perforation is the weakest part of the material, the majority of stretching will occur in the section of the material provided with the perforation, and the perforation may be stretched until a breaking point is reached. The exact amount of stretch/tension that is needed to separate wipes depend on the material used, and the amount may be determined using experiments and stored in memory of the control unit CU.

In one embodiment, the control unit CU is further configured to control the machine 100 to increase tension of the material 110 in a section of the path 712 to separate the material 110 at a generated perforation 310. Additionally, or alternatively, the section of the path is located between the first tension unit 160 and the folding unit 180. Additionally, or alternatively, the material 110 is separated into parts when the generated perforation is located after the perforation unit 170, e.g., two parts. Additionally, or alternatively, the material 110 is separated into parts, e.g., two parts, when the generated perforation is located in proximity to or at the inlet of the folding unit 180.

In one example, this relative movement/speed of the material through the machine (in the length direction) before the folding unit 180 is controlled to be less/lower than the relative movement/speed of the material through the folding unit 180. This increases tension in a section of the path 712 between the machine and the folding unit 180, the section comprising a perforation. This increased tension causes the perforation to break between adjacent wipes, thereby separating the material 110 into two parts.

FIG. 4B shows a perforation after separation of wipes according to one or more embodiments of the present disclosure.

In FIG. 4B the perforation shown in FIG. 4A is stretched until the perforation breaks and adjacent wipes are separated.

The folding unit 180 may separate a first wipe close to or in its inlet (not shown), thereby allowing the second/next wipe to be fed into the folding unit 180. The second/next wipe then forms the first wipe in the next stack of folded wipes 192.

FIG. 5A shows a side view of a stack of folded wipes 192 according to one or more embodiments of the present disclosure.

As can be seen from FIG. 5A, the stack of folded wipes 192 comprises continuous material/web provided with or using perforations. The stack 192 comprises perforations illustrated by the thicker vertical lines on the right-hand side of the stack 192.

As can be seen in FIG. 5A, the material 110 is folded across/orthogonal to the length direction of the material with a particular width or distance between folds w. The material is folded in alternating directions and forms a zig-zag pattern of folded wipes. It is understood that any suitable folding pattern may be used as such as a V-folded Z-folded or M-folded configuration or any other folding pattern well known to those skilled in the art.

Each stack of folded wipes 192 typically comprises a selected number N of wipes that forms the stack of folded wipes 192. N may be any number 1 or greater. The number N for pop-up wipes is typically 2 wipes or more.

FIG. 5B shows a top view of a stack of folded wipes 192 according to one or more embodiments of the present disclosure. The generated stack of wipes 192 has a width w, a length I, and a selected number N of wipes.

As can be seen in FIG. 5A, the material 110 is folded across/orthogonal to the length direction of the material with a particular width or distance between folds w. In some embodiments, a perforation is positioned between each wipe at a distance d from the outer edge of the stack/from the fold. Depending on the container used, this distance may differ, although the perforation is generally arranged along a center w/2 of each wipe, or in the middle of folds, at least for the wipe on the top of the pile.

FIG. 6 shows a path 112 of material threaded through the machine 100 according to one or more embodiments of the present disclosure. The path 112 is illustrated as a thick solid line. The direction of the path or path direction runs from the holder 1111 to the stacking unit 190.

FIG. 7A shows an example of a section of the path 712 according to one or more embodiments of the present disclosure.

In this example, the section of the path is shown as a solid thick line. The section of the path runs from the first tension unit 160 to the folding unit 180, via the perforation unit 170.

FIG. 7B shows a further example of a section of the path 712 according to one or more embodiments of the present disclosure.

In this example, the section of the path is shown as a solid thick line. The section of the path runs from the perforation unit 170 to the folding unit 180 via the first tension unit 160. The dashed line illustrates the remaining path 112 through the machine 100.

FIG. 8 illustrates details of a folding unit 180 according to one or more embodiments of the present disclosure.

The folding unit 180 is configured to produce stacks of folded wipes 192 from the material 110. In one embodiment, the folding unit comprises two or more folding rollers 850, 860 configured to receive the material 110 and generate folded stacks of wipes 192.

As mentioned previously, the two or more folding rollers 850, 860 are configured to fold the material in alternating directions effectively forming a zig-zag pattern as further described in FIG. 5 and FIG. 11A-C. In other words, the two or more folding rollers 850, 860 are configured to interact with each other to generate the folded wipes 191.

Each folding roller 850, 860 comprises a hub 801, 802, wherein the hub 801, 802 comprises one or more grippers 831, 832, 841, 842 configured to grip and release the material 110. The folding unit further comprises one or more infeed plates 821, 822, 823, 824 configured to feed the material 110 to the one or more grippers 831, 832, 841, 842. The respective gripper then holds the material 110 during a certain rotation of the roller, and then releases the material 100, e.g., when the material is gripped by the other roller.

Optionally, each roller further comprises intermediate elements 811-814 forming the outer surface on which the material rests upon.

In one example, a first infeed plate 822 on a first roller 850 protrudes from the outer surface of the respective roller, and as the roller/s rotate the first infeed plate 822 feeds/pushes the material 110 to a respective first gripper 841. The roller 860 then rotates a certain amount, corresponding to the width w, shown in relation to FIG. 5. A second infeed plate 823 on the second roller 860 protrudes from the outer surface of the second roller, and as the roller/s rotate the second infeed plate 823 feeds/pushes the material 110 to a respective second gripper 832.

FIG. 9 shows the control unit 900 according to one or more embodiments of the present disclosure. The control unit 900 may be in the form of e.g., an Electronic Control unit, a server, an on-board computer, a stationary computing device, a laptop computer, a tablet computer, a handheld computer, a wrist-worn computer, a smart watch, a smartphone, or a smart TV. The control unit 900 may comprise a processor/processing circuitry 912, optionally communicatively coupled to a communications interface 904, e.g., a transceiver configured for wired or wireless communication.

In one example, the processing circuitry 912 may be any of a selection of processing circuitry and/or a central processing unit and/or processor modules and/or multiple processors configured to cooperate with each-other.

Further, the unit 900 may further comprise a memory 915. The memory 915 may e.g., comprise a selection of a hard RAM, disk drive, a floppy disk drive, a flash drive or other removable or fixed media drive or any other suitable memory known in the art. The memory 915 may contain instructions executable by the processing circuitry to perform any of the steps or methods described herein.

The processing circuitry 912 may optionally be communicatively coupled to a selection of any of the communications interface 904, the memory 915, one or more sensors, such as position sensors. The control unit 900 may be configured to send/receive control signals directly to any of the above-mentioned units or to external nodes. E.g., to send control signals to the holder 111 of the material.

The communications interface 904, such as a wired network adapter and/or a wired, may be configured to send and/or receive data values or parameters as a signal to or from the processing circuitry 912 to or from other external nodes. E.g., rotational position of rollers. In an embodiment, the communications interface 904 communicates directly to external nodes.

In one or more embodiments the control unit 900 may further comprise an input device 917, configured to receive input or indications from a user and send a user input signal indicative of the user input or indications to the processing circuitry 912.

In one or more embodiments the control unit 900 may further comprise a display 918 configured to receive a display signal indicative of rendered objects, such as text or graphical user input objects, from the processing circuitry 912 and to display the received signal as objects, such as text or graphical user input objects.

In one embodiment the display 918 is integrated with the user input device 917 and is configured to receive a display signal indicative of rendered objects, such as text or graphical user input objects, from the processing circuitry 912 and to display the received signal as objects, such as text or graphical user input objects, and/or configured to receive input or indications from a user and send a user-input signal indicative of the user input or indications to the processing circuitry 912.

In a further embodiment, the control unit 900 may further comprise and/or be coupled to one or more additional sensors (not shown in the figure) configured to receive and/or obtain and/or measure physical properties pertaining to the machine 100, and send one or more sensor signals indicative of the physical properties of the machine 100 to the processing circuitry 912.

In one or more embodiments, the processing circuitry 912 is further communicatively coupled to the communications interface 904 and/or the input device 917 and/or the display 918 and/or the controllable power exchange unit 917 and/or the sensors and/or the additional sensors and/or any of the units described herein.

Moreover, it is realized by the skilled person that the control unit 900 may comprise the necessary communication capabilities in the form of e.g., functions, means, units, elements, etc., for performing the present solution. Examples of other such means, units, elements and functions are: processors, memory, buffers, control logic, encoders, decoders, rate matchers, de-rate matchers, mapping units, multipliers, decision units, selecting units, switches, modulators, demodulators, inputs, outputs, antennas, amplifiers, receiver units, transmitter units, DSPs, MSDs, TCM encoder, TCM decoder, power supply units, power feeders, communication interfaces, communication protocols, etc. which are suitably arranged together for performing the present solution.

Especially, the processing circuitry and/or processing means of the present disclosure may comprise one or more instances of processing circuitry, processor modules and multiple processors configured to cooperate with each-other, Central Processing Unit (CPU), a processing unit, a processing circuit, a processor, an Application Specific Integrated Circuit (ASIC), a microprocessor, a Field-Programmable Gate Array (FPGA) or other processing logic that may interpret and execute instructions. The expression “processing circuitry” and/or “processing means” may thus represent a processing circuitry comprising a plurality of processing circuits, such as, e.g., any, some or all the ones mentioned above. The processing means may further perform data processing functions for inputting, outputting, and processing of data comprising data buffering and device control functions, such as user interface control, or the like.

In one embodiment, a machine 100 is provided and is configured to produce stacks of folded wipes 192 from material 110, wherein the material 110 is threaded along a path 112 through the machine 100, the machine comprising a holder 111 of the section of material 110, a first tension unit 160, the folding unit 180 described herein, a control unit CU, 900 communicatively coupled to at least the first tension unit 160 and the folding unit 180, the control unit CU comprising a processor, and a memory, said memory containing instructions executable by said processor, wherein the material 110 is threaded along a path 112 through the machine 100 via at least the first tension unit 160 and the folding unit 180, wherein the control unit CU is configured to control the folding unit 180 to generate stacks of wipes 192 by controlling angular velocity ω-350, ω-360 of rollers 350, 360 comprised in the folding unit 180 dependent on predetermined characteristics.

FIG. 10 shows a flowchart of a method 1000 according to one or more embodiments of the present disclosure. In one embodiment, the method 1000 is provided. The method 1000 is performed by the machine 100 described herein. The method comprises 1010 controlling the machine 100 to produce folded wipes, e.g., pop-up wipes, 192 by individually controlling tension of material 110 along one or more sections of the path 712. The method further comprises 1020 controlling the machine to increase tension of the material 110 in a section of the path 712 to stretch a generated perforation 310 in the section of the path 712 by a target distance ΔS. In one embodiment, the section of the path 712 is located after the perforation unit 170.

In one embodiment, the section of the path 712 is located between the first tension unit 160 and the folding unit 180.

In one example, the control unit CU controls the tension in a section of the path 712 between the first tension unit 160 and the folding unit 180 e.g., by controlling rotational position and/or angular velocity of rollers in the respective unit. In other words, the material moves at different rates or velocity through the first tension unit 160 and the folding unit 180 thereby increasing the tension in a section of the path 712 comprising the perforation 310 until the perforation is stretched by the target distance ΔS. This may involve moving/rotating rollers in the first tension unit 160 relative to movement/rotation of rollers in the folding unit 180. This relative movement/rotation will increase tension in the material in the particular section of the path 712 provided with the perforation 310. As the perforation is the weakest part of the material, the majority of stretching will occur in the section of the material provided with the perforation, and the perforation may be stretched the target distance ΔS. The exact amount of stretch/tension that is needed depends on the material used, and the amount may be determined using experiments and stored in memory of the control unit CU.

In one embodiment, the method further comprises controlling the machine to increase tension of the material 110 in a section of the path 712 to separate the material 110 at a generated perforation 310. This is further described in relation to FIG. 4A and FIG. 4B.

In other words, the perforation may be stretched the target distance ΔS such that two adjacent wipes are separated, and the path/material is separated into at least two parts.

In one embodiment, the method further comprises the section of the path 712 is located between the first tension unit 160 and the folding unit 180.

In one embodiment, the material 110 is separated into parts when the generated perforation is located after the perforation unit 170. In one example, the material 110 is separated into parts, e.g., a first part comprising material from the holder 111 to the perforation, and a second part comprising material from the perforation until the last wipe of the stack.

In one example, the control unit CU controls the tension in a section of the path 712 between the first tension unit 160 and the folding unit 180 e.g., by controlling rotational position and/or angular velocity of rollers in the respective unit. In other words, the material moves at different rates or velocity through the first tension unit 160 and the folding unit 180 thereby increasing the tension in a section of the path 712 comprising the perforation 310 until the perforation is stretched to a breaking point and adjacent wipes are separated. This may involve moving/rotating rollers in the first tension unit 160 relative to movement/rotation of rollers in the folding unit 180. This relative movement/rotation will increase tension in the material in the particular section of the path 712 provided with the perforation 310. As the perforation is the weakest part of the material, the majority of stretching will occur in the section of the material provided with the perforation, and the perforation may be stretched until a breaking point is reached. The exact amount of stretch/tension that is needed to separate wipes depend on the material used, and the amount may be determined using experiments and stored in memory of the control unit CU.

This has the advantage that both the pulling force required to separate wipes can be adapted within a stack 192, and the continuous web of folded wipes 191 can be parted into stacks of folded wipes 192 using the same functionality. In other words, no additional parts or arrangements are needed to separate the continuous web of folded wipes 191 into stacks of folded wipes 192. This provides a cheaper, more flexible, and more reliable operation of the machine 100.

In one embodiment, the method further comprises controlling the machine to adjust tension of the material 110 in a section of the path 712 located after the perforation unit 170 and before the folding unit 180 to adjust the relative location of a perforation 310 generated by the perforation unit 170 in a produced stack of folded wipes 192.

In one embodiment, the method further comprises controlling the machine to adjust material velocity through the folding unit 180 to adjust the relative location of a perforation generated by the perforation unit 170 in a produced stack of folded wipes 192.

In one example, the control unit CU controls the material velocity through the folding unit 180 in a section of the path 712 between the first tension unit 160 and the folding unit 180 e.g., by controlling rotational position and/or angular velocity of rollers in the respective unit. In other words, the material moves at different rates or velocity through the first tension unit 160 and the folding unit 180 thereby adapting the length of material in a section of the path 712 to adjust the position of the perforation relative to a respective fold of the folding unit 180. This may involve moving/rotating rollers in the first tension unit 160 relative to movement/rotation of rollers in the folding unit 180. This relative movement/rotation will adjust the position of the perforation relative to a respective fold of the folding unit 180 to ensure that a perforation of the topmost wipe is at a distance w/2 from the fold/edge of the stack. The exact adjustment of position may be predetermined and stored in memory of the control unit CU.

In one embodiment, a computer is provided and comprises instructions which, when the program is executed by the computer, cause the computer to carry out the methods described herein.

In one embodiment, a control unit CU is provided and comprises instructions which, when the program is executed by the computer, cause the computer to carry out the methods described herein.

In one embodiment, a computer program product is provided and comprises instructions which, when the program is executed by a computer/control unit CU, cause the computer/control unit CU to carry out the methods described herein.

In one embodiment, a computer-readable storage medium is provided and comprises instructions which, when executed by a computer, cause the computer to carry out the methods described herein.

FIG. 11A illustrates a V-folding pattern. The stack 192 comprises perforations illustrated by the thicker lines on the left-hand side of the stack 192. I.e., distance d is =0 or w.

As can be seen in the figure, the stack of wipes 192 comprises continuous material using perforations. E.g., a continuous web provided with perforations to enable the continuous material to be separated into parts or separate wipes.

FIG. 11B illustrates a Z-folding pattern. The stack 192 comprises perforations illustrated by the thicker lines on the center of the stack 192. I.e., distance d is =w/2.

FIG. 11C illustrates a M-folding pattern. The stack 192 comprises perforations illustrated by the thicker lines on the left-hand side of the stack 192 every four wipes. I.e., distance d is =0 or w.

FIG. 12 illustrates a stack comprising wipes having multiple formats, e.g., a care pack. As can be seen, the produced stack 192 comprises a first wipe of length 4×w, two shorter wipes of length 2×w and a wipe of length 6×w.

Finally, it should be understood that the invention is not limited to the embodiments described above, but also relates to and incorporates all embodiments within the scope of the appended independent claims.

MACHINE CONFIGURED TO PRODUCE STACKS OF FOLDED WIPES

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