Folding Former Nose With Angled Air Outlets for Web Friction Control
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Solution Overview
Problem
Existing former designs face challenges in supplying sufficient quantities of blowing air to the leg surfaces of folding formers, leading to issues such as substrate deposition, increased wear, and web tension problems due to inadequate air distribution.
Innovation Solution
A former nose design featuring an angular offset between the first and second extensions of the blow air ducts, allowing for closer spacing and uniform air distribution, combined with an additive manufacturing process to maintain the substrate-guiding geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If blow air ducts are installed on leg surfaces of conventional formers, then air cushion is formed to reduce friction and wear, but the blowing air cannot reach sufficient extent in the area of the funnel legs and leg surfaces due to substrate deflection, leading to substrate deposition and web tension problems
Solution Approach 1:
The patent introduces a third dimension (angular offset) to the blow air duct configuration. Instead of only varying the position along the leg surface, the ducts are angled relative to the cover surface edge, creating a three-dimensional air distribution pattern that penetrates through the deflected substrate more effectively, ensuring air reaches the critical areas between funnel legs and substrate.
Solution Approach 2:
The patent changes the geometric parameters of the blow air duct configuration by defining specific angular relationships. The first extension forms an angle of 15°-75° with the cover surface edge, and the second extension forms an angle of 15°-75° with the first extension. This parameter optimization ensures air is directed precisely where needed despite substrate deflection.
2Ease of operation
If former noses are manufactured with complex angular offset geometry to achieve uniform air distribution, then air supply effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent defines specific angular parameter ranges (15°-75° for both extensions) that balance performance and manufacturability. These standardized parameter ranges allow for consistent manufacturing while achieving the desired air distribution uniformity, avoiding overly complex geometries that would be difficult to produce.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures low friction and reduced wear by providing high-volume air supply without compromising the substrate-guiding contour, resulting in improved product quality and extended component life.
Implementation Method 1
outlets for the discharge of blown air, which forms an air cushion between the substrate to be folded and the funnel nose
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The invention relates to a funnel nose 1 for a folding funnel 10 for folding a web- or arc-shaped substrate running in the transport direction X, comprising a cover surface 2 with two cover surface edges 3 tapering to a point in the transport direction X, over which the substrate is transported in the area of a fold to be formed, and adjacent to each of the cover surface edges 3 a curved leg surface 4, wherein at least one blow air channel 5 for the outflow of pressurized blow air emerges from each leg surface 4, the blow air channel 5 having an outlet surface 6 on the respective leg surface 4. Furthermore, the present invention relates to a folding funnel 10 with a funnel nose 1 according to the invention and a method for manufacturing a funnel nose 1 according to the invention.The invention is based on the objective of providing a solution by which blown air can be supplied to the area of the leg surfaces 4 in sufficient quantity and reliably, without significantly impairing the contour of the leg surfaces 4. This objective is achieved by providing at least one outlet surface 6 with a first extension a and a second extension b, wherein the first extension a is larger than the second extension b.