|Title of Invention||
A MACHINE TO PRODUCE SURGICAL BANDAGES AND A PROCESS FOR MANUFACTURING SURGICAL BANDAGES"
|Abstract||A machine to produce surgical bandages and a process to manufacture the surgical bandages are state of the art machine and technology most useful to resolve the existing problems of shrinkages, manual stretching of edges, improper longitudinal tensions in the bandage cloth, low value addition to the output, high cost of production, employment of a large number of workers, requirement of skilled work force, production of high fatigue, drudgery, poor product quality, requirement of a number of operations and improper hygienic conditions of production caused by using the existing obsolete machine, the traditional and conventional processes of manufacture. The problems are overcome by the present invention which provides a machine comprising a width control mechanism (11] to hold the edges of the bandage cloth to prevent shrinkages and eliminate the requirement of stretching the edges of the cloth, a friction device [15, 16, 17] to create frictional forces and optimum tension in the bandage cloth, a tachometer  to measure the exact length of the bandage cloth and eliminate 6 existing operations of cloth unfolding, spreading, holding manually, marking, rolling on beam and making the master roll as the present invention does not require these operations because the cloth is directly fed to the machine for rolling, yielding high product quality, low cost of production, higher productivity, least fatigue, negligible drudgery, high value addition to the output enabling the machine, the technology and the product to capture larger share in the global market and attract heavy demand in the local & national markets.|
|Full Text||1 TITLE
A machine to produce surgical bandages and a process for manufacturing surgical bandages.
The invention relates to "A machine to produce surgical bandage and "A process for manufacturing surgical bandages". The existing machine which produces surgical bandages suffers from a large number of disadvantages and drawbacks for want of proper design and suitable technology of manufacture. Some of the important drawbacks and disadvantages are as under:-
a) The machine does not cater for automatic removal of shrinkages of the bandage cloth during manufacture.
b) The machine necessarily requires the edges of the bandage cloth to be stretched manually which produces heavy human errors, fatigue, drudgery and drastically reduces the quality of output.
c) The machine does not provide any device or gadget which can measure the exact length of the bandages during their production. This forces the requirements of pre-marking of length of bandages before commencing the production.
d) The machine does not have any Kinematic device with adjustable elements which can after the longitudinal tension in the cloth to desired magnitude for controlling the quality of output. This draw back forces the machine to he made with additional members making it heavier, costly, voluminous inconvenient for operation and grouting.
e) The process for manufacturing requires a large number of operations and forces deployment of a large number of skilled, semiskilled & unskilled workforce.
f) The cost of machine is too high as majority of machine elements are made of good quality timber with over use of materials.
g) The design of the machine caters for only manual driving except in a very few cases it is driven mechanically where as provisions of manual as well a mechanical driving is considered to be advantageous and essential for productivity.
Besides the above mentioned problems, the existing machine and the process for manufacturing have a large number of other problems also like the productivity is extremely low, quality of product is poor, the cost of machine is extremely high due to its poor efficiency, improper design, use of costlier materials, low sheet life etc. Keeping all these problems in mind, a state-of-the Art machine has been designed with development of cutting edge technology & process for manufacture.
3. SUMMARY OF PRESENT INVENTION
The draw backs, weaknesses and problems of the existing machine and process for manufacturing surgical bandages are eliminated and resolved in the present invention, which provides a stat-of-the-art machine consisting of a frame, a friction bearing, rubberized rollers a width control mechanism, a tachometer and a cutting edge technology for manufacturing the surgical bandages. The frame is designed and fabricated using latest technology and to achieve low weight and high strength ratio, metallic materials are used in its manufacture. The frame is the main structure which assembles its other assembles, machine elements and parts. The friction bearing comprises a cap, a spring, a shoe, a base and a bolt. The bearing controls the rotation of rubberized rollers. The rubberized rollers calender the bandage cloth and guide it to the width control mechanism. The friction bearing and the rubberized rollers, jointly provide desired tension in the cloth and eliminate the need of a number of extra machine elements of meant for creating tension. The existing machine.
The width control mechanism is an assembly of conveyer chains, having a large number of integral pints to held the edges of the cloth, the gears, the nuts, the power screw the channels and commercial components. The function of the mechanism is to monitor the width of the cloth as required and maintain its dimensional stability. The design caters for increasing or decreasing the distance between the chains and setting them parallel or as re angle to each other to the suit the conditions of production. The tachometer is mounted at the rear end of the frame facing the roll making operator and meters the specified length of the surgical bandage during their manufacture. This instrument eliminates a number of existing operations.
The process for manufacturing the surgical bandages, eliminates most of the operations of the existing process and has got only a few operations to
accomplish the task and deploy only a small work force. It possesses a high potential to yield value added outputs, enhance productivity, reduce fatigue, drudgery, production cost, increase competitiveness qualities, capture larger share in thee global market and sell like a hot cake in the markets. The machine the technology rand the products will have extremely bright future for export and uses in the national,, local & global markets.
To assist with understanding the existing machine and the process of manufactture and the Invention, parameters, details, advantages, drawbacks of existing rmachine, processes and the invention are given in Table - 1 with details of operation Schedule in Table - 2.
STATEMENT OF INVENTION
A machine to produce surgical bandages which comprises frame (20), characterized in that the machine is provided with, the width control mechanism (11) and channel (12) to control the width of the cloth of surgical bandage, Friction bearing (17) to optimize the longitudinal tension in the bandage cloth by optimizing the clearance between rubberized rollers (15, 16) which are assembled in the struts (21, 22) tachometer assembly (4) interfaced with the frame (20) to measure the length of the bandage cloth rolled, the conveyer chains (2) which remain parallel or inclined to each other.
4 BRIEF DESCRIPTION OF DRAWINGS
Fig. 1 Shows existing machine
Fig. 2 Shows existing processes for manufacture
Fig. 3 Shows invented machine
Fig. 4 Shows improved technology and process for manufacture
5. DETAILED DESCRIPTION OF MACHINES AND PROCESSES
Referring to Fig, 1, it can be seen that the design of the existing machine caters for a handled (1) to rotate roll making bar (4), guides (2, 3) to regulate cloth, a frarme (5) to interface necessary assemblies and components. The design of the machine is traditional disadvantages. The frame (5) is made of wooden material, strengthened by metallic stays (6) and provided with machine elements (7, 11, 12) to create friction in the cloth for obtaining longitudinal tension in it during the process of manufacture. The cloth on receipt, is opened, spread, bandage length marked and rolled over the beam (9). The assembly is called master roll and is placed at the cantilevers (8,10). The free end of the cloth is pulled through machine elements (7, 11, 12), guides (2,, 3) and fastened to bar (4). Struts (13,14) are provided to facilitate production.
Fig. 2 shows the existing machine in operation and the process for manufacturing surgical bandages. The free end of the cloth (17) from the master roil (18) is attached to the roll making bar. The bar is connected to the driving system (20). The handle of the system (20) is rotated manually and in a few cases mechanically which inturn rotates the bar and the cloth (17) rolls ower it. One of the major disadvantages of the machine and the process is, that during production the cloth (17) heavily shrinks and necessitates its edges
[15,16] to be manually stretched [15,16]. This drawback reduces product quality tremendously, produces high fatigue and drudgery. Also it reduces productivity, increase cost of production, promotes wastivity and leads towards sideness of the industry. When the specified bandage length is rolled, the rotation is stopped, cloth  is slit, the roll  is wrapped with brown paper and the same is detached from the machine for next operation of cutting it into specified sizes of surgical bandages. The production process consist of 8 operations and deploys 8 workmen including skilled, semiskilled and unskilled personnel.
Referring to Fig.-3, it is found that the machine to produce surgical bandages according to this Invention comprises mainly the frame , the width control mechanism , the friction bearing , the rubberized rollers [15,16], the roll making bar , the driving handle  and the tachometer  . The frame  is the basic structure consisting of struts [21,22], stays , guides [7,8] and the channel . The frame interfaces subassemblies and the parts of the machine. IT is fabricated from metallic materials using cutting edge technologies and state-of-the-art design parameters.
The width control mechanism consists of a power screw  and the nut assembly . The nut assembly is fitted with a channel  a train of gears [3,14,23], conveyer chain , pins . There are 2 nut assemblies & one each is placed over the channel  at its ends and form a running fit. Both the nuts are connected with the power screw  & the distance between the nuts can be increased or decreased by rotating the screw. The power screw is fitted to the channel  through antifriction bearings and firmly held at its ends. The design of the mechanism provides for setting the conveyer chains  in parallel to each other and also in the inclined configuration such that the distance between chains at the front end nearer to the rubberized rollers [15,16] can be made smaller to facilitate proper gripping and engagement of cloth by the pins . The with control mechanism  performs critical functions to provide even and proper cloth width, eliminate manual stretching operation, remove loose threads of the bandage, improve quality of output, enhance productivity, add high value to the product, reduce fatigue, drudgery and create excellent demand in the national and international markets for the machine, the process technology and the product.
The friction bearing  is an important sub/assembly which contains the cap, the shoe, the base, the bolt, the spring and commercial fasteners. The bearing is lubricated by a suitable lubricant and performs the functions of
providing required gap between the rubberized rollers [15,16] and the optimum tension to the cloth . The bearing assembly is made of metallic and non metallic materials and the rubberized rollers are metallic tubes coated with rubber and ends plugged. The rollers [15,16] calender the cloth and create desired longitudinal tension in it. For interfacing, the base is positioned over the struts [21,22] followed by roller , springs of the bearings  roller , the shoe and the bearing cap and the bolt. The complete assembly is firmly held with the struts [21,22] with the help of commercial fasteners. The roll making bar  is held between the opposite members of the frame through spring loaded plungers and one of the plungers is coupled with driving system . When the handle  is rotated the bar  also rotates and rolls the cloth  over it. The tachometer , is interfaced with the frame  facing the operator and measures the specified length of surgical bandages during the process of rolling.
Fig.-4 shows the process for manufacturing surgical bandages as per the inventions. The process starts with loosening of bolts [28,29], As the bolts loosen, the upper rubberized roller  lifts upward due to the force exerted by the spring of the bearing assembly and creates clearance between the rollers. The cloth bundle  is positioned in front of the rubberized rollers directly without performing the operations of spreading, holding, marking, rolling on the beam making the master roll and assembling the same master roll on the machine as required in the existing process for manufacturing surgical bondages. The free end of the cloth  is directly inserted between the rubberized rollers eliminating the above mentioned 6 existing operations of the current process and required length of the cloth is pulled. The bolts [27,28] are tightened to decrease the clearance and provide necessary longitudinal tension in the cloth . The edges of the cloth  the pulled cloth is spreaded over the conveyer chains of the width control mechanism and its edges are held by the pins of the conveyer chains. The end of the remaining portion of the cloth  is passed through the guides and fastened to the roll making bar. The roll making bar is rotated through the driving system  and the cloth  rolls over the bar to form roll . The design also caters for rotating the bar  mechanically. The transverse tension of the cloth  is monitored through the rotation of handle  of the power screw and the manual stretching operations of the existing process is completely removed. A machine, a process technology and the out put will have matchless characteristics sufficient to capture local, national and global markets.
TABLE -1 : ADVANTAGES OF INVENTIONS OVER EXISTING MACHINE
1. A machine to produce surgical bandages which comprises frame (20),
characterized in that the machine is provided with,
the width control mechanism (11) and channel (12) to control the width of the cloth of surgical bandage, Friction bearing (17) to optimize the longitudinal tension in the bandage cloth by optimizing the clearance between rubberized rollers (15,16) which are assembled in the struts (21,22), tachometer assembly (4) interfaced with the frame (20) to measure the length of the bandage cloth rolled, the conveyer chains (2) which remain parallel or inclined to each other.
2. A machine to produce surgical bandages as claimed in claim 1, where in roll making bar (6) is assembled with the frame (20), which is driven by handle (5) or a mechanical device.
3. A machine to produce surgical bandages as claimed in claim 2, where in guide (7,8) are provided to support and guide the cloth to the roll making bar (6).
4. A Machine to produce surgical bandages as claimed in claim 1, where in
width control mechanism (11) consists of power screw (13), nut assembly
(19), channel (18), train of gears (3,14, 23), conveyer chain (2), and pin (1) to
provide even and proper cloth width.
5. A machine to produce surgical bandages as claimed in claim 4, where in
power screw (13) is fitted to the channel (12) through antifriction bearings.
6. A Process for manufacturing surgical bandages by the machines as claimed in
claim 1, where in the process comprising the steps of:
(a) Loosing the bolts (28,29) to lift the upper rubberized roller (16).
(b) Positioning the cloth bundle in front of the rubberized rollers.
(c) Inserting the free end of the cloth between the rubberized rollers.
(d) Tightening the bolts (27,28) to decrease the clearance between rollers and
provide the longitudinal tension.
(e) Pulling the edges of cloth and spreading over the conveyor chains.
(f) Passing the cloth (25) through the guides and fastened to the roll making bar.
(g) Rotating the bar through the driving system to form the cloth roll.
7. A Machine to Produce Surgical Bandages and a Process for manufacturing Surgical Bandages, substantially as herein described with reference to the foregoing description and figures.
|Indian Patent Application Number||2143/DEL/2005|
|PG Journal Number||02/2011|
|Date of Filing||12-Aug-2005|
|Name of Patentee||RAMANJOR YADAV|
|Applicant Address||C-2/2408 VASANTKUNJ, NEW DELHI-110070, INDIA.|
|PCT International Classification Number||A61F 13/02|
|PCT International Application Number||N/A|
|PCT International Filing date|