AN AUTOMATIC WRITING INSTRUMENT PRODUCTION MACHINE

Abstract

The present disclosure relates to a machine (102) for producing paper-based writing instruments. The machine (102) includes a paper feeding unit (104) configured to stack and feed a plurality of paper sheets into the machine (102). An adhesive application unit (114) is configured to receive the plurality of paper from the paper feeding unit (104), and apply a layer of adhesive to the paper sheets. The machine (102) further includes an insertion unit (128) that inserts a marking substrate (154), such as graphite lead or ink refill, into at least one paper sheet (156). Additionally, a rolling unit (136) wraps the at least one paper sheet (156) tightly around the marking substrate (154), forming a complete writing instrument. The automated process enables efficient, high-precision production of paper-based writing instruments, with reduced material wastage and minimal manual intervention.

Specification

Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to production of writing instrument, and more particularly, relates to an eco-friendly fully automatic paper-based writing instrument producing machine, and a method for using the same.

BACKGROUND
[0002] The widespread use of plastic-based writing instruments, such as pens and pencils, has become a significant environmental concern. These products contribute to the growing problem of plastic waste, which persists in landfills and oceans for hundreds of years, causing harm to ecosystems and wildlife. Additionally, the production of the plastic based writing instruments often involves the use of non-renewable resources and energy-intensive manufacturing processes, further exacerbating their adverse environmental impact.
[0003] In response to these issues, there has been a growing interest in paper-based alternatives for writing instruments. Paper, being biodegradable and derived from renewable resources, offers a more environmentally friendly option. However, the production of paper-based writing instruments has presented several challenges. Traditional manufacturing methods for paper-based writing instruments often involve complex, multi-step processes that are difficult to automate efficiently. This complexity results in higher production costs and limited scalability, making it challenging to produce the paper-based writing instruments in large quantities at competitive prices.
[0004] Furthermore, the quality and durability of the paper-based writing instruments have been concerns, as they must meet consumer expectations for performance and longevity comparable to their plastic counterparts. Achieving consistent quality in rolling and assembly of the paper-based writing instruments has proven to be a significant hurdle in their widespread adoption.
[0005] Thus, there is a clear need for a solution that may help produce the paper-based writing materials, such as pencils and pens efficiently, significantly reducing plastic waste disposal.

OBJECTS OF THE PRESENT DISCLOSURE
[0006] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.
[0007] It is an object of the present disclosure to provide an eco-friendly, fully automatic machine for the production of paper-based writing instruments, such as pencils and pens.
[0008] It is an object of the present disclosure to provide to improve the precision and efficiency of the production process by introducing a compact, space-efficient design that ensures accurate feeding, adhesive application, and insertion of the marking substrate (e.g., graphite lead or ink refill).
[0009] It is an object of the present disclosure to minimize manual intervention in the production process, thereby reducing human error, improving throughput, and enhancing overall productivity.
[00010] It is an object of the present disclosure to provide an automated solution that is adaptable to different types of marking substrates and diameter of writing instrument, thereby enhancing the versatility and applicability of the machine across various writing instruments.

SUMMARY
[00011] This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter
[00012] Aspects of the present disclosure relate to the production of paper-based writing instruments. In particular, the present disclosure provides a machine for producing paper-based writing instruments, and a method for using the same.
[00013] An aspect of the present disclosure pertains to a machine for producing paper-based writing instruments. The machine includes a paper feeding unit configured to stack and feed a plurality of paper sheets into the machine. The machine further includes an adhesive application unit configured to successively receive the plurality of paper sheets from the paper feeding unit, and configured to apply a layer of adhesive to the plurality of paper sheets. The machine also includes an insertion unit configured to insert a marking substrate into at least one paper sheet from the plurality of paper sheets coated with the adhesive. The machine includes a rolling unit configured to successively receive the plurality of paper sheets from the insertion unit, wrap that at least one paper sheet around the marking substrate inserted thereinto, forming a writing instrument.
[00014] In an aspect, the plurality of paper sheets has a tapered design.
[00015] In an aspect, the adhesive application unit includes a first roller partially submerged in an adhesive reservoir, and configured to apply the layer of adhesive to a portion of the at least one paper sheet. The adhesive application unit also includes a second roller positioned above and in contact with the first roller to support the plurality of paper sheets as the plurality of paper sheets pass between the first roller and the second roller. The adhesive application unit further includes a third roller partially submerged in the adhesive reservoir and positioned adjacent to the first roller on a side opposite to the second roller to apply another layer of adhesive on another portion of the at least one paper sheet.
[00016] In an aspect, the insertion unit includes a belt drive insert unit that temporarily pauses the movement of the plurality of paper sheets to allow precise insertion of the marking substrate.
[00017] In an aspect, the insertion unit includes a lead screw, and a bolt connected to a carriage, where when the lead screw is rotated, the bolt is configured to advance or retract along a longitudinal direction on the lead screw based on direction of rotation of the lead screw. The carriage may be configured to align and position the marking substrate on the at least one paper sheet when advanced or retracted by the bolt.
[00018] In an aspect, the rolling unit includes a belt drive unit having a first belt and a second belt configured to rotate at varying speeds to wrap the at least one paper sheet around the marking substrate therebetween (i.e., between the first belt and the second belt).
[00019] In an aspect, the plurality of sheets moves downwards by the force of gravity from the adhesive application unit to the insertion unit, ensuring proper orientation and alignment.
[00020] In an aspect, the machine includes an ejection unit configured to receive the completed writing instrument from the rolling unit for packing.
[00021] Another aspect of the present disclosure pertains to a method for using a machine for producing paper-based writing instruments. The method includes stacking and feeding, by a paper feeding unit of a machine, a plurality of paper sheets into the machine. The method further includes applying, by an adhesive application unit of the machine, a layer of adhesive to the plurality of paper sheets. Further, the method includes inserting, by an inserter unit of the machine, a marking substrate into at least one paper sheet from the plurality of paper sheets coated with the adhesive. Furthermore, the method includes wrapping, by a rolling unit of the machine, each paper sheet around the marking substrate inserted into the at least one paper sheet, forming a writing instrument.
[00022] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[00023] The accompanying drawings, which are incorporated herein, and constitute a part of the present disclosure, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. It will be appreciated by those skilled in the art that such drawings include the electrical components, electronic components or circuitry commonly used to implement such components.
[00024] FIG. 1A illustrates a cross-sectional view of a machine for producing paper-based writing instruments, in accordance with an embodiment of the present disclosure.
[00025] FIG. 1B illustrates a perspective view of the machine, in accordance with an embodiment of the present disclosure.
[00026] FIG. 1C illustrates a perspective view of an adhesive application unit of the machine, in accordance with an example of the present disclosure.
[00027] FIG. 1D illustrates a cross-sectional view of an insertion unit of the machine, in accordance with an embodiment of the present disclosure.
[00028] FIGs. 1E and 1F illustrate a side view of the rolling unit, in accordance with an embodiment of the present disclosure.
[00029] FIG. 2 illustrates a flow diagram of a method for using an automatic paper-based writing instrument producing machine in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[00030] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may
[00031] The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the scope of the disclosure as set forth.
[00032] Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.
[00033] The word "exemplary" and/or "demonstrative" is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as "exemplary" and/or "demonstrative" is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms "includes," "has," "contains," and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive like the term "comprising" as an open transition word without precluding any additional or other elements.
[00034] Reference throughout this specification to "one embodiment" or "an embodiment" "an instance" or "one instance" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[00035] The terminology used herein is for the purpose of describing particular features embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items
[00036] In an aspect, the present disclosure pertains to machines for producing paper-based writing instruments, and a method for using the same. The machine includes a paper feeding unit configured to stack and feed a plurality of paper sheets into the machine. The machine further includes an adhesive application unit configured to successively receive the plurality of paper sheets from the paper feeding unit, and configured to apply a layer of adhesive to the plurality of paper sheets. The machine also includes an insertion unit configured to insert a marking substrate into at least one paper sheet of the plurality of paper sheets coated with the adhesive. The machine includes a rolling unit operatively connected to the insertion unit and is configured to wrap the at least one paper sheet around the marking substrate inserted thereinto, forming a writing instrument.
[00037] Various embodiments of the present disclosure will be explained in detail with reference to FIG. 1A- 2.
[00038] FIGs. 1A and 1B illustrate example representations 100A and 100B of a machine 102 for producing paper-based writing instruments, in accordance with an example of the present disclosure. In an example, the writing instruments may include, but are not limited to, pencils, pens, markers, highlighters, crayons, coloured pencils, and the like. In an example, the machine 102 may be configured to produce these writing instruments using paper as a primary material for outer casing, thereby reducing plastic waste and promoting environmental sustainability.
[00039] With reference to FIGs. 1A, the machine 102 includes a paper feeding unit 104 that is configured to stack and feed a plurality of paper sheets (such as multiple ones of paper sheet 156 shown in FIGs. 1E and 1F). The paper feeding unit 104 includes a paper loading plate 106 to support the paper sheets 156. As shown in FIG. 1A, the paper loading plate 106 is positioned at an angle. This angled configuration of the paper loading plate 106 may serve to feed the paper sheets 156 into the machine 102 (or adhesive application unit 114 thereof) using gravity assistance or an operable motor connected to a guide roller 108, ensuring a consistent and controlled supply of the paper sheets 156 to the subsequent components of the machine 102. In an example, the paper sheets 156 may be stacked and fed into the machine 102 one by one. In some embodiments, the paper sheets 156 may have a tapered design, which may facilitate the wrapping process and ensures a smooth, uniform writing material body. In some embodiments, the paper sheets 156 may have a tapering width such that an edge or nib of the marking substrate, when attached to the paper sheet 156, may be visible/accessible after paper sheet 156 is rolled to form the writing instrument. In other embodiments, paper sheets 156 may be tapered in thickness from one end to another.
[00040] In an embodiment, adjacent to the paper loading plate 106, the guide roller 108 may be installed. In an example, the guide roller 108 may be configured to pull and direct the paper sheets 156 from the paper feeding unit 104 as they move through the machine 102. In an example, the paper sheet 156 may be made to pass underneath the guide roller 108, which may help keep the paper sheet 156 straight as the paper sheet 156 moves through the guide roller 108, thereby maintaining proper alignment and preventing misfeeds or jams. In an embodiment, beneath the guide roller 108, a support plate 110 may be positioned. In an example, the support plate 110 may provide a stable surface for the paper sheets 156 as they are fed into the machine 102, ensuring smooth movement and preventing any unwanted bending or folding of the paper sheets 156. As shown in FIG. 1B, in an embodiment, the machine 102 may include a guide roller motor 112 that may rotate the guide roller 108 during operation of the machine 102. In an example, the guide roller motor 112 may be a variable speed motor, allowing for precise control of the paper feed rate. In another example, the guide roller motor 112 may be equipped with sensors to detect paper sheet jams or misfeeds, automatically adjusting its speed, or stopping if necessary to prevent damage to the paper sheet or the machine 102.
[00041] In an embodiment, the machine 102 includes an adhesive application unit 114 that is connected to the paper feeding unit 104. The adhesive application unit 114 may be configured to receive the paper sheets 156 from the paper feeding unit 104, and apply a layer of adhesive to the paper sheets 156. The adhesive application unit 114 may include a first roller 116, which may be configured to apply the adhesive to the paper sheet 156. To ensure a consistent supply of the adhesive, the first roller 116 may be partially submerged in an adhesive tray 118, which may act as a reservoir for the adhesive. In some embodiments, to apply the layer of adhesive to the paper sheets, each paper sheet 156 may be fed, for example, by the rotation of the guide roller 108, to the first roller 116 of the adhesive application unit 114, where a lower surface of the paper sheet 156 facing the first roller 116 may be coated with the adhesive on coming into contact with the partially submerged first roller 116. In an example, the first roller 116 may apply adhesive to either the entire lower surface or a specific area of the lower surface of the paper sheets 156, depending on the design requirements of the writing instrument being produced.
[00042] In an embodiment, the adhesive application unit 114 may further include a second roller 120. The second roller 120 may be positioned above and in contact with the first roller 116, supporting the paper sheets 156 as they pass between the first roller 116 and the second roller 120. The second roller 120 may be configured to prevent the paper sheet 154 from derailing when making contact with the first roller 116. In another embodiment, the adhesive application unit 114 may include a third roller 122. The third roller 122 may be partially submerged in the adhesive reservoir, and positioned adjacent to the first roller 116 to eliminate the collection of excess glue on the first roller 116 and retain the excess glue within the adhesive tray 118, thereby maintaining a uniform layer of adhesive for application across the entire lower surface of the paper sheets 156. The second roller 120 and the third roller 122 may be configured to support the position and/or operation of the first roller 116. Other aspects of the adhesive application unit 114 are described subsequently in the present disclosure in reference to FIG. 1C.
[00043] In an embodiment, the guide roller 108, the first roller 116, the second roller 120, and the third roller 122 of the adhesive application unit 114 may be supported on the machine 102 through guide plates 124A, 124B provided on both sides of the machine 102, as illustrated in FIG. 1B. These guide plates 124A, 124B serve as structural supports, allowing for positioning and alignment of the rollers 116, 120, and 122 within the machine 102. The guide plates 124A, 124B extend along the sides of the machine 102, providing mounting points for axles of the rollers 116, 120, and 122. The guide plates 124A, 124B may also serve as a housing for the machine 102, and may be configured to securely position all components of the machine 102 at a predetermined relative distance from the other.
[00044] In an embodiment, the machine 102, as shown in FIG. 1B, may include a first roller motor 126 configured to rotate the first roller 116 (and the third roller 122), cause the paper sheets 156 to pass through the adhesive application unit 114. This motorized rotation of the first roller 116 and the third roller 122 facilitates the continuous movement of the paper sheets 156 through the adhesive application process, ensuring a steady and controlled flow of the adhesive. In an example, speed of the first roller motor 126 may be adjustable to accommodate different paper thicknesses or adhesive application requirements, allowing for precise control over the adhesive layer application. In an embodiment, the machine 102 may be designed to support a gravity-driven flow mechanism, where once the paper sheets 156 are coated with the adhesive, the paper sheets 156 flow downwards with the assistance of gravity, and driven by the rotation of the first roller 116. This controlled descent of the paper sheets 156 may ensure that the paper sheets 156 reach the next stage/unit in the correct orientation and without disruption.
[00045] In an embodiment, the adhesive used in the adhesive application unit 114 may include, but is not limited to, a water-based adhesive, a solvent-based adhesive, a hot melt adhesive, a pressure-sensitive adhesive, an ultraviolet-curable adhesive, a biodegradable adhesive, a starch-based adhesive, a protein-based adhesive, a synthetic polymer adhesive, a natural rubber-based adhesive, or the like.
[00046] In an embodiment, the machine 102 may include an insertion unit 128 that is configured to insert a marking substrate (such as marking substrate 154 of FIGs. 1D to 1F) into each of the paper sheets 156 that are coated with the adhesive. In an example, the insertion unit 128 may include a belt drive insert unit that may temporarily pause the movement of the paper sheets 156, for example, by causing the first roller motor 126 to stop the movement of the first roller 116 to allow precise insertion of the marking substrate 154.
[00047] In an embodiment, once a paper sheet is temporarily stopped, a lead screw and a bolt of the insertion unit 128 may align and position the marking substrate 154 within the adhesive-coated paper sheet 156 by advancing or retracting the marking substrate 154 into the correct position using a carriage 130 for wrapping. In an embodiment, a lead screw and a bolt mechanism may include a precision-threaded lead screw that, when rotated, moves a matching bolt attached to a carriage 130 holding the marking substrate. The lead screw may be rotated to either advance and/or retract the bolt along a longitudinal direction on the lead screw based on direction of rotation of the lead screw. In some embodiments, the carriage 130 may be configured to receive the marking substrate 154 from the refiller bucket 148, and align and position the marking substrate 154 on the at least one paper sheet 156 when advanced or retracted by the bolt, thereby precisely inserting the marking substrate 154 into the adhesive layer on the paper sheet 156 inside the belt drive unit. The rotation of the lead screw, controlled by a stepper or servo motor, may translate into precise linear motion of the carriage 130, allowing for accurate positioning of the marking substrate relative to the paper sheet. The number of rotations of the lead screw required for inserting or retracting the carriage 130 for inserting the marking substrate 154 may be determined based on the type of lead screw, its pitch, and the servo motor. The lead distance indicative of the distance that the carriage 130 is required to be moved is given by the formula:
Lead distance=Pitch * Number of starts
In some embodiments, the lead screw may be a single-start threaded lead screw, and the motor's rotation is controlled by time. In an example, an 8 mm pitch is selected, as it is commonly used in 3D printing machines for accurate, high-precision movements. Other aspects of the insertion unit 128 are described subsequently in reference to FIG. 1D.
[00048] In an embodiment, the marking substrate 154 may include graphite leads for pencil production and/or ink refill for the pen production. In an example, the machine 102 is configured to handle various diameters and lengths of the marking substrate 154.
[00049] In an embodiment, the insertion unit 128 may include a marking substrate loader 132 that may be configured to hold the marking substrate 154, and may be actuated by a marking substrate motor 134 to load the marking substrate 154 to the carriage 130 for wrapping the same in the paper sheet 156 coated with the adhesive. In an example, the marking substrate loader 132 may include a multi-compartment storage capable of holding various types and sizes of the marking substrates 154 simultaneously. In another example, the marking substrate loader 132 may include adjustable dividers to accommodate different lengths and diameters of the marking substrates 154.
[00050] In an embodiment, the machine 102 may include a rolling unit 136 configured to receive the paper sheet 156 from the insertion unit 128. The rolling unit 136 may be configured to wrap each paper sheet 156 around the marking substrate 154 to form a writing instrument once the marking substrate 154 is inserted/fixed to the paper sheet 156. The rolling unit 136 may include a belt drive unit having a first belt 138-1 and a second belt 138-2, which may be configured to rotate at varying speeds to provide the tight wrapping of the paper sheets 156 over the marking substrate 154. In an example, after the marking substrate 154 is positioned on the adhesive-coated paper sheet 156, the insertion unit 128 may push the combined adhesive-coated paper sheet 156 and the marking substrate 154 positioned therein between the first belt 138-1 and the second belt 138-2. The differential rotation speeds and directions of the first belt 138-1 and the second belt 138-2 may cause the marking substrate 154 to rotate, and wrap the paper sheet 156 around the marking substrate 154. This process may effectively transform the flat, adhesive-coated paper sheet 156 with the positioned marking substrate 154 thereover into a substantially cylindrical writing instrument. The varying rotation speeds of the belts 138-1, 138-2 may allow for precise control over the wrapping process, accommodating different paper thicknesses, marking substrate sizes, or desired tightness of the wrap. This ensures consistent and high-quality production of paper-based writing instruments across various specifications and designs.
[00051] In an embodiment, the rotation of the first belt 138-1 and the second belt 138-2 at varying speeds may be achieved using dedicated motors. In an example, a first belt motor 140-1 may be coupled to the first belt 138-1, while a second belt motor 140-2 may be coupled to the second belt 138-2. These motors may be independently controlled to drive their respective belts at different rotational velocities. The ability to adjust the speed of each belt individually may allow for precise control over the wrapping process, enabling the machine 102 to accommodate different paper thicknesses, marking substrate sizes, or to achieve specific wrapping tensions. This independent motor configuration may provide the flexibility needed to optimize the wrapping process for various types of writing instruments being produced.
[00052] In an embodiment, the machine 102 may include an ejection unit 142 connected to the rolling unit 136. The ejection unit 142 may be a container configured to receive the completed writing instrument for packaging or further processing. In an example, the ejection unit 142 may be a tray, a conveyor belt, a chute, or a sorting mechanism. In some implementations, the ejection unit 142 may include a multi-compartment system to sort writing instruments based on different criteria such as size, colour, or type. In some implementations, the ejection unit 142 may also be equipped with a cushioning mechanism to ensure gentle handling of the newly produced writing instruments, preventing damage during the ejection process.
[00053] FIG. 1C illustrate example representation 100C of the adhesive application unit 114 of the machine 102, in accordance with an example of the present disclosure.
[00054] In reference to FIGs. 1A and 1C, the first roller 116 of the adhesive application unit 114 may be provided with one or more wedge-shaped needles 144. In an example, a tip of each needle 144 may be inside a groove 146 provided on the first roller 116. The needles 144, positioned in the grooves 146, may create a slight elevation in the paper sheet 156 path without making direct, hard contact with the paper sheet 156. This allows for gentle guidance of the paper sheet 156 as it exits the first roller 116 after application of the adhesive. By relying on surface contact rather than hard contact, the needles 144 may minimize disturbance to the freshly applied adhesive layer. This helps maintain the integrity and uniformity of the glue coating. Further, surface contact results in less friction compared to hard contact, reducing wear on both the paper sheet 156 and the needles 144 over time. The tips of the needles 144 in the grooves 146 may create a subtle lift effect as the first roller 116 rotates, facilitating a controlled separation of the paper sheet 156 from the first roller 116 surface without direct interference. This arrangement allows for precise control over the path of the paper sheet 156 immediately after the adhesive application, ensuring that the paper sheet 156 follows the intended route through the machine 102 without sticking to the first roller 116. Further, the needles 144, by lifting the paper sheets 156, may allow gravity to pull the paper sheets 156 down to the insertion unit 128. Thus, by placing the needles 144 in the grooves 146 may allow for smooth, continuous operation by preventing the paper sheet 156 from adhering to or wrapping around the first roller 116, all without applying direct pressure to the paper sheet 156 or adhesive layer.
[00055] In an embodiment, the first roller 116 may be of a continuous cylindrical shape along its entire length. This design may enable a continuous and uniform adhesive application process. The cylindrical shape may help maintain consistent adhesive distribution across the paper sheet surface, enhancing the quality and reliability of the adhesive application. The continuous application of the adhesive may contribute to increased production speeds and reduced interruptions in the manufacturing workflow.
[00056] FIG. 1D illustrate an example representation 100D of the insertion unit 128 of the machine 102, in accordance with an example of the present disclosure.
[00057] In reference to FIG. 1D, the insertion unit 128 includes a refiller bucket 148. In an example, the refiller bucket 148 serves as a storage container for the marking substrate 154. The refiller bucket 148 may have a curved shape that guides the marking substrate 154 towards the bottom along the paper sheet 156 that comes down from the first roller 116.
[00058] In an embodiment, the insertion unit 128 may include a refiller inlet 150 positioned at the top of the refiller bucket 148. In an example, the refiller inlet 150 is an opening that may allow for the introduction of new marking substrate 154 into the machine 102. The refiller bucket 148 may also include an opening, through which the marking substrate 154 may exit the refiller bucket 148, and rest over a carriage 130.
[00059] In an embodiment, the insertion unit 128 may include a guide block 152 for the marking substrate 154. In an example, the guide block 152 may extend from the top of the refiller bucket 148 to the bottom, defining a path for the marking substrate 154 to follow as the marking substrate 154 moves downward towards the opening. The guide block 152 helps to align and orient the marking substrate 154 correctly as the marking substrate 154 approaches the area where the marking substrate 154 is to be aligned with the paper sheet.
[00060] Furthermore, the insertion unit 128 may include the carriage 130. The carriage 130, located at below the insertion unit 128, is designed to move horizontally, as indicated by the bidirectional arrow in FIG. 1D. In some embodiments, the carriage 130 may be caused to move by a motor. The motor may be rotatably connected to the screw, and the carriage 130 may be connected to the bolt attached to the screw. As the screw is caused to rotate by the motor, the rotation of the screw may be translated to linear motion of the bolt. Since the bolt is attached to the carriage 130, the carriage 130 may move linearly along with the bolt. The direction of linear movement of the carriage 130 may be controlled by the direction of rotation of the screw.
[00061] In some embodiments, the carriage 130 may be moved linearly or extended or advanced towards the direction of the paper sheet 156, until the marking substrate 154 resting thereover comes into contact with the layer of adhesive on the paper sheet 156. The carriage 130 has a depression or seating area where the marking substrate 154 may rest, until it comes into contact with the adhesive, and is inserted into the paper sheet 156. In some embodiments, the marking substrate 154 is inserted/fixed to the paper sheet 156, the carriage 130 may be retracted, by reversing the direction of rotation of the screw. FIG. 1D shows the marking substrate 154 in seating position on the carriage 130. The arrangement of these components allows for a controlled and sequential insertion of the marking substrate 154.
[00062] This design enables efficient and precise handling of the marking substrate 154, ensuring a smooth and continuous supply for the writing instrument production process. The curved shape of the refiller bucket 148 and the guide block 152 work together to orient the marking substrate 154 correctly, while the movable carriage 130 facilitates the insertion of individual marking substrates 154 to the paper sheet.
[00063] FIGs. 1E and 1F illustrate example representations 100E and 100F of the rolling unit 136, in accordance with an example of the present disclosure.
[00064] As shown in FIGs. 1E and 1F, the first belt 138-1 and the second belt 138-2 of the rolling unit 136 may have a longitudinal offset. This offset arrangement may create tension between the first belt 138-1 and the second belt 138-2, facilitating tight rolling of the paper sheet 156 around the marking substrate 154. The tension generated by this offset may enable precise and secure wrapping of the paper sheet around the marking substrate 154, contributing to the formation of a well-constructed paper-based writing instrument. The offset positioning of the first belt 138-1 and the second belt 138-2 may allow for continuous and controlled rolling action, ensuring consistent quality in the production process.
[00065] For example, when the marking substrate 154 is enters into the rolling unit 136, as shown in FIG. 1E, the marking substrate 154 may be only connected to with the paper sheet 156. When the belts 138-1 and 138-2 rotate, the paper sheet 156 may be caused to wrap around the marking substrate 154, as shown in FIG. 1F. For example, when the second belt 138-2 rotates in a clockwise direction (with respect to the view shown in FIGs. 1E and 1F), the paper sheet 156 and the marking substrate may be moved from left to right direction (with respect to the view shown in FIGs. 1E and 1F). In some embodiments, the first belt 138-1 also rotates concurrently with the second belt 138-2, the marking substrate 154 may be caused to rotate in an anti-clockwise direction (with respect to the view shown in FIGs. 1E and 1F). When the marking substrate 154 rotates, the paper sheet 156 may be configured to wrap/roll over the marking substrate 154. Once a predetermined number of layers of the paper sheet 156 are wrapped around the marking substrate 154, the writing instrument may be formed, which may be ejected out from the machine 102. In some embodiments, the first belt 138-1 may be configured to rotate slower than the second belt 138-2, to allow the marking substrate 154 to rotate, while moving the marking substrate from left to right direction.
In an embodiment, the paper feeding unit 104, adhesive application unit 114, the insertion unit 128, the rolling unit 136, and the ejection unit 142 may be removable from the machine 102. This allows for any component of the machine 102 to be detached from the machine 102 without disturbing other components or arrangements. Such a design may facilitate easy cleaning and maintenance of the glueing components, potentially reducing downtime and improving overall machine 102 hygiene. The machine 102 has a compact footprint, optimizing space utilization in production environments.
[00066] FIG. 2 illustrates a flow diagram of a method for using an automatic paper-based writing instrument producing machine in accordance with an embodiment of the present disclosure.
[00067] With reference to FIG. 2, at step 202, the method 200 includes feeding a plurality of paper sheets into a machine (such as machine 102 for FIGs. 1A to 1E) using a paper feeding unit 104 of the machine 102. The paper feeding unit 104 ensures that the paper sheets 156 are properly aligned and introduced into the machine 102 for further processing. For example, a stack of tapered paper sheets 156 designed may be placed on the paper feeding unit 104, which may feed the paper sheet 156 into an adhesive application unit 114 of the machine 102, while ensuring that each paper sheet 156 moves sequentially into the machine 102.
[00068] At step 204, the method 200 includes applying a layer of adhesive to the plurality of paper sheets 156 using the adhesive application unit 114. The adhesive applied by the adhesive application unit 114 may bond the paper sheet 156 tightly around the marking substrate 154. For example, after the paper sheet 156 fed into the adhesive application unit 114, the adhesive is coated to the side of the paper 156 that eventually wraps around the marking substrate 154.
[00069] At step 206, the method 200 includes inserting, using an insertion unit such as insertion unit 128 of FIGs. 1A to 1E, the marking substrate (e.g., graphite lead or ink refill, such as marking substrate 154 shown in FIG. 1D) into the adhesive-coated paper sheet. The insertion unit 128 may ensure precise positioning of the marking substrate 154 on the paper sheet. The insertion unit 128 may include use a carriage (such as carriage 130 of FIG. 1D) connected to bolt configured move linearly along the length of a screw on rotation thereof. The carriage 130 may be advanced towards the paper sheet 156 to insert the making substrate 154 thereinto, and retracted thereafter.
[00070] At step 208, the method 200 includes wrapping each paper sheet 156 around the marking substrate 154 using a rolling unit, such as the rolling unit 136 of FIGs. 1A to 1E. The paper sheet 156 may be wrapped tightly around the marking substrate 154 to create the writing instruments. For example, the paper sheet 156, now coated with adhesive and holding the marking substrate 154, enters the rolling unit 136, where one or more belts or rollers (such as belts 138-1 and 138-2 shown in FIGs. 1E and 1F) tightly wrap the paper sheet 156 around the marking substrate 154 to form the writing instruments.
[00071] While the foregoing describes various embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope thereof. The scope of the present disclosure is determined by the claims that follow. The present disclosure is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the present disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[00072] The present disclosure provides a fully automated process for producing paper-based writing instruments, eliminating the need for manual intervention, thus improving efficiency and reducing labour costs.
[00073] The present disclosure provides for precise feeding, adhesive application, and wrapping process which reduces material wastage, ensuring that paper and adhesive are used efficiently, thus contributing to cost savings and environmental benefits.
[00074] The present disclosure provides a sequential operation of multiple motors, each controlling a specific unit of the machine, allowing for faster production cycles while maintaining high precision.
[00075] The present disclosure allows the machine to be easily scaled for mass production, making it suitable for large-scale manufacturing operations, thereby catering to high demand in the market.
[00076] The present disclosure provides a rolling unit of the machine is designed to tightly and uniformly wrap the paper around the marking substrate, ensuring proper alignment and tight enclosure.
, Claims:1. A machine (102) for producing paper-based writing instruments, comprising:
a paper feeding unit (104) configured to stack and feed a plurality of paper sheets;
an adhesive application unit (114) configured to successively receive the plurality of paper sheets from the paper feeding unit (104), and apply a layer of adhesive to the plurality of paper sheets;
an insertion unit (128) configured to insert a marking substrate (154) into at least one paper sheet (156) from the plurality of paper sheets coated with the adhesive; and
a rolling unit (136) configured to successively receive the plurality of paper sheets from the insertion unit (128), and wrap the at least one paper sheet (156) around the marking substrate (154) inserted thereinto, forming a writing instrument.

2. The machine (102) as claimed in claim 1, wherein the plurality of paper sheets comprises a tapered design.

3. The machine (102) as claimed in claim 1, wherein the adhesive application unit comprises:
a first roller (116) partially submerged in an adhesive reservoir, configured to apply the layer of adhesive to a portion of the at least one paper sheet (156);
a second roller (120) positioned above and in contact with the first roller (116) to support the plurality of paper sheets as the plurality of paper sheets pass between the first roller (116) and the second roller (120); and
a third roller (122) partially submerged in the adhesive reservoir and positioned adjacent to the first roller (116) on a side opposite to the second roller (120) to apply another layer of adhesive on another portion of the at least one paper sheet (156).

4. The machine (102) as claimed in claim 1, wherein the insertion unit (128) comprises:
a lead screw; and
a bolt connected to a carriage (130), wherein when the lead screw is rotated, the bolt is configured to advance or retract along a longitudinal direction on the lead screw based on direction of rotation of the lead screw, and wherein the carriage (130) is configured to align and position the marking substrate (154) on the at least one paper sheet (156) when advanced or retracted by the bolt.

5. The machine (102) as claimed in claim 4, wherein the insertion unit (128) comprises a belt drive insert unit that temporarily pauses the movement of the plurality of paper sheets to allow precise insertion of the marking substrate (154).

6. The machine (102) as claimed in claim 1, wherein the rolling unit (136) comprises a first belt (138-1) and a second belt (138-2) configured to rotate at varying speeds to wrap the at least one paper sheet around the marking substrate (154) therebetween.

7. The machine (102) as claimed in claim 1, wherein the plurality of paper sheets moves downwards by the force of gravity from the adhesive application unit (114) to the insertion unit (128).

8. The machine (102) as claimed in claim 6, further comprising an ejection unit (142) configured to receive the completed writing instrument from the rolling unit (136).

9. A method (200) for using a machine (102) for producing paper-based writing instruments, comprising:
feeding (202), by a paper feeding unit (104) of a machine (102), a plurality of paper sheets;
applying (204), by an adhesive application unit (114) of the machine (102), a layer of adhesive to the plurality of paper sheets;
inserting (206), by an inserter unit (128) of the machine (102), a marking substrate (154) into at least one paper sheet (156) from the plurality of paper sheets coated with the adhesive; and
wrapping (208), by a rolling unit (136) of the machine (102), the at least one paper sheet (156) around the marking substrate (154) inserted thereinto, forming a writing instrument.

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