Loop Folding System for Variable Sheet Configurations
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Solution Overview
Problem
Existing paper folding systems require multiple pairs of rollers to achieve various fold configurations, leading to increased cost and complexity, and often result in paper jams due to inadequate handling of extended sheet portions during folding.
Innovation Solution
A system with a single pair of folding rollers, a pocket-like channel, and a curved guiding path that maintains the rollers' rotational direction, utilizing an inducing element and deflecting flaps to guide and reposition the sheet for C-fold, Z-fold, or half-fold configurations, ensuring smooth operation and reduced jam risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pairs of folding rollers are used to achieve various fold configurations, then the folding capability and versatility are improved, but the device complexity and cost increase
Solution Approach 1:
A single pair of folding rollers is designed to perform multiple folding operations (C-fold, Z-fold, half-fold) by combining them with a pocket-like channel and curved guiding path that directs the sheet through different trajectories. The same rollers can create different fold configurations depending on how the sheet is guided into and out of the folding area, eliminating the need for multiple dedicated roller pairs for each fold type.
Solution Approach 2:
The invention adds spatial dimensionality through the pocket-like channel and curved guiding path that wrap around the rollers. By utilizing the three-dimensional space around the rollers and creating loop paths, the system achieves multiple fold configurations without adding more rollers, effectively using spatial arrangement to multiply the functional capacity of the single roller pair.
2Adaptability or versatility
If multiple pairs of folding rollers are used to achieve various fold configurations, then the folding capability is improved, but the manufacturing cost increases
Solution Approach 1:
The single pair of folding rollers serves multiple folding functions (C-fold, Z-fold, half-fold) when combined with the pocket-like channel and curved guiding path. This multi-functionality reduces the total number of rollers needed, thereby lowering manufacturing costs while maintaining versatile folding capability across different sheet configurations.
Solution Approach 2:
The invention merges the functions of multiple rollers into a single roller pair by combining them with the pocket-like channel and guiding path structure. This consolidation reduces the number of individual components that need to be manufactured and assembled, directly reducing manufacturing complexity and cost while achieving the same versatile folding outcomes.
3Productivity
If the sheet is pushed through folding rollers to form folds, then the folding operation is completed, but paper jams occur when the sheet extension is not properly caught
Solution Approach 1:
The pocket-like channel is designed to pre-position and guide the sheet extension into the correct trajectory before it reaches the folding rollers. By preparing the sheet's path in advance through the curved guiding path, the system ensures that the sheet extension is properly caught and directed during the folding operation, preventing jams before they can occur.
Solution Approach 2:
The curved guiding path acts as an intermediary element between the sheet and the folding rollers. It mediates the sheet's movement, ensuring smooth transition and proper positioning of the sheet extension as it approaches the rollers, thereby reducing the risk of improper catching and subsequent paper jams during the folding process.
Data Source
Figure 1~1A
Figure 2~3
Figure 4~5
AI summary
A system for selectively C, Z or half-folding sheet(s) of paper of variable format, comprising: - a pocket-like channel (10) with a stop element (12) for defining a paper sheet position and positioning the sheet(s) according to a location of a recipient's address A and a type of fold required, - two folding rollers (2, 4) arranged diametrically opposite to each other and forming a folding/nipping area (6), - an inducing element (8) movable towards and away from the folding/nipping area for defining a fold line position, and - a curved guiding path (14, 16, 18, 20, 22, 24, 26) which substantially covers at least one of the two folding rollers for receiving and guiding the sheet(s) completely around one or the other of the two folding rollers without changing their rotational direction during the folding cycle.