Hook-Shaped Folding Element for Padded Part Production
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Solution Overview
Problem
Existing methods for folding upholstery parts are either costly, complex, or do not ensure a safe and simple folding process, lacking efficiency in producing circumferential side surfaces.
Innovation Solution
A method involving a fold line positioning element and a folding element that alternately move to create multiple fold sections, with a hold-down element forming circumferential side surfaces, and a folding device with a hook-shaped or U-shaped folding element to guide and form the sections, allowing for rapid and cost-effective production of upholstered parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing folding methods are used, then folding can be achieved, but the process is costly and complex
Solution Approach 1:
The folding device is divided into distinct functional segments: a fold line positioning element that defines fold lines, a folding element that performs the actual folding motion, and a hold-down element that secures folded sections. This segmentation allows each component to perform its specific function independently, simplifying the overall device while maintaining manufacturing precision.
Solution Approach 2:
The fold line positioning element automatically defines the fold line position through its geometric relationship with the blank, eliminating the need for complex positioning mechanisms. The folding element naturally guides the folding motion through its design, and the hold-down element self-positions to secure folded sections, reducing the need for additional control systems.
2Productivity
If existing folding methods are used, then folding can be achieved, but production time is excessive
Solution Approach 1:
The fold line positioning element is positioned in advance to define all necessary fold lines before the folding process begins. This preliminary positioning eliminates the need for real-time measurement and adjustment during folding, allowing the folding element to move directly to predetermined positions and significantly reducing overall process time.
Solution Approach 2:
The folding element moves continuously along the blank, creating multiple fold sections in a single uninterrupted motion. The hold-down element remains engaged throughout the process to maintain pressure on folded sections, eliminating idle time between folding operations and ensuring continuous productive action.
3Manufacturing precision
If fold sections are created without precise positioning, then folding is simpler, but the shape and right angles of side surfaces cannot be ensured
Solution Approach 1:
The fold line positioning element serves as an intermediary between the blank and the folding element. It translates the desired precise fold line positions into a simple geometric relationship with the blank, allowing the folding element to create accurate fold sections without requiring complex positioning controls. The positioning element acts as a mediator that simplifies the transmission of positioning information.
4Manufacturing precision
If multiple folding steps are performed sequentially, then precise folding can be achieved, but the process becomes complex and time-consuming
Solution Approach 1:
Multiple folding operations are merged into a single continuous folding motion. The folding element creates multiple fold sections in one pass, and the hold-down element maintains engagement throughout, combining what would traditionally be separate sequential steps into one integrated operation. This merging maintains precision while dramatically improving efficiency.
Data Source
Figure 1~2b
Figure 2c~2f
Figure 2g~2j
AI summary
The invention relates to a device for folding a cushioning part for packaging from a blank, comprising a folding table on which the blank is mounted, a folding line positioning element which defines a folding line to be generated with an edge, and a movable folding element by means of which a folding section of the blank is folded at an angle from a blank plane around a folding line defined by the folding line positioning element, wherein the movable folding element is designed in a hook shape.