Compressing Winder Assembly for Fibrous Blankets
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Solution Overview
Problem
Existing methods for packaging fiberglass blankets are inefficient in compressing and winding multiple blankets into a single roll, leading to creases and the need for unfolding before use.
Innovation Solution
A system comprising a conveyor, winder feed chute with compression surfaces, and a compressing winder assembly that overlaps and compresses fibrous blankets as they are wound, using rollers and a mandrel to create a compact roll with sufficient friction to maintain the blankets in position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple fibrous blankets are stacked and compression packed into bags or boxes, then the blankets can be stored and transported, but the process is inefficient and creates creases that require unfolding before use
Solution Approach 1:
The patent changes the physical state and arrangement parameters of the blankets by transitioning from stacked folding to continuous overlapping and winding. The blankets are fed in a continuous manner with overlapping edges, compressed under controlled pressure, and wound into rolls, which eliminates creases while maintaining compactness for storage and transport.
Solution Approach 2:
Instead of folding and stacking blankets horizontally then compressing them vertically in bags, the patent inverts the approach by winding the blankets into rolls along their length. This inversion of the packaging geometry allows the blankets to be compressed along their entire length continuously, preventing crease formation while maintaining ease of manufacture.
2Productivity
If fibrous blankets are wound into a roll using the compressing winder assembly, then the blankets can be efficiently stored and dispensed, but the blankets must be overlapped and compressed to maintain position
Solution Approach 1:
The patent merges the compression function and winding function into a single integrated compressing winder assembly. The compression rollers apply pressure to the overlapping blankets while the mandrel simultaneously winds them into a roll. This combination of functions improves productivity by eliminating separate compression and winding operations while the integrated design manages the complexity through functional integration.
Solution Approach 2:
The overlapping portion of the blankets acts as an intermediary element between the compression rollers and the winding mandrel. This overlap zone allows the compression force to be transmitted effectively to the roll structure, maintaining blanket position during winding. The winder feed chute also serves as an intermediary structure that guides and positions the blankets for optimal compression and winding.
3Manufacturing precision
If the spacing between compression surfaces is reduced to compress blankets, then the blankets are compacted effectively, but the spacing must be precisely controlled to allow overlapping blankets to pass through
Solution Approach 1:
The patent employs dynamic compression where the spacing between compression surfaces is adjusted based on the feeding process. The compression is applied progressively as blankets are fed through the winder feed chute and onto the mandrel. This dynamic approach allows sufficient initial spacing for overlapping blankets to pass through easily, then applies increasing compression as the roll builds, achieving uniform compression without blocking the feed process.
Solution Approach 2:
The compression is applied locally at specific zones along the blanket length rather than uniformly across all blankets simultaneously. The winder feed chute creates a localized compression zone where overlapping portions are compressed, while other portions remain uncompressed and easily feedable. This local quality approach maintains ease of operation in feed zones while achieving manufacturing precision in compression zones.
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 system effectively compresses and winds multiple fiberglass blankets into a single roll, reducing creases and eliminating the need to unfold the blankets prior to use, while allowing for efficient dispensing and storage.
Implementation Method 1
At least a portion of the spacing between the lower compression surface and the upper compression surface is sufficient to allow two overlapped fibrous blankets moving thereby to be compressed together
Implementation Method 2
the overlapped portion of the two blankets may move through a compression zone of a winder feed chute
Implementation Method 3
create a compact roll with sufficient friction to maintain the blankets in position
Implementation Method 4
compressing winder assembly is downstream from the winder feed chute and in communication with the winder feed chute exit
Data Source
AI summary
In the description and drawings methods and apparatus for the compression and winding of a plurality of overlapped fibrous blankets are disclosed. The methods and apparatus may allow a leading edge of a trailing blanket to be overlapped with a trailing edge of a leading blanket that is being wound by a compressing winder assembly. As the compressing winder assembly winds the leading blanket, the trailing blanket may be moved downstream by the leading blanket and an overlapped portion of the two blankets may move through a compression zone of a winder feed chute.