Automatic Rewinder for Air Bubble Film Using Expandable Spindles
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Solution Overview
Problem
Current rewinding machines for air bubble plastic film and similar materials face inefficiencies due to the use of cardboard cores, which require gluing, lead to downtime, and result in irregular reel extraction and damage to the film, while discontinuous processes lengthen production times and reduce productivity.
Innovation Solution
An automatic rewinding machine with two winding stations using leaf expandable spindles and a motor-driven cylindrical brush for efficient winding without cores or glues, ensuring constant speed and even film wrapping through a cutting assembly that cuts the film at a distance from the spindle, allowing for continuous production without core-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cardboard cores are used for winding film, then the film can be wound and stored, but the process requires gluing, loading downtime, and increases production time
Solution Approach 1:
The patent removes the cardboard core from the winding system entirely. The film is wound directly onto expandable spindles without requiring separate core loading and gluing operations. This extraction of the core element eliminates the associated downtime and simplifies the winding process, directly addressing the productivity-time contradiction.
Solution Approach 2:
The spindles are pre-prepared with an expandable structure that can be quickly deployed. Before winding begins, the spindle is in a compact state, and during operation it expands to receive the film. This preliminary preparation eliminates the need for on-site core assembly and gluing, reducing production downtime.
2Reliability
If cardboard cores with glue are used, then film can be secured during winding, but the gluing process and core handling increase complexity and maintenance needs
Solution Approach 1:
The patent eliminates the cardboard core and gluing system entirely. Film security is achieved through the mechanical expansion of the spindle itself, which creates friction and physical containment without requiring adhesive materials or complex gluing equipment, thereby reducing device complexity while maintaining winding stability.
Solution Approach 2:
The expandable spindle structure provides its own film-retention mechanism through radial expansion. The spindle self-generates the necessary holding force via its expanding leaves, eliminating the need for external gluing systems or core assemblies, thus simplifying the overall device while ensuring reliable film winding.
3Productivity
If film is wound at high speed, then productivity increases, but the film may not wind evenly and may form pockets
Solution Approach 1:
The film end is pre-positioned and guided onto the expanding spindle before high-speed winding begins. The initial film layers are established during the expansion phase, creating a stable foundation that prevents pocket formation even at high winding speeds, thus maintaining both productivity and precision.
Solution Approach 2:
The spindle transitions from a static to a dynamic expanding state during winding initiation. This dynamic expansion creates a progressive gripping action that ensures even film distribution from the start, allowing high-speed operation without sacrificing winding uniformity. The expanding leaves dynamically adapt to the film width and tension.
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 machine enables continuous, efficient, and uniform winding of air bubble plastic film, increasing production rates by eliminating core-related downtimes and costs, ensuring even film wrapping along the spindle, and preventing damage to the film, thus enhancing productivity and reducing production time.
Implementation Method 1
at least two shafts of said two stations for the winding are leaf expandable shafts comprising a plurality of circular sectors moving radially with respect to the axis of the respective shaft
Implementation Method 2
a motor-driven cylindrical brush for facilitating the winding of the cut flap of said sheet of film on the winding shaft to be wound
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
A description is given of an automatic rewinding machine (100) for the rewinding of an air bubble film (3) (or similar materials such as PE foam, XPS foam, and others) comprising rotating support means (6) suitable for supporting one end of a respective horizontal leaf expandable winding shaft (4) whereon a first reel A will be formed, and one end of at least one other horizontal rotating leaf expandable winding shaft (4',4"), said winding shafts forming at least one winding station and a reel unloading station, cutting means (20) suitable for cutting a film of air bubble plastic (or similar materials such as PE foam, XPS foam, and others) characterised in that it provides wrapping means (30), placed opposite to said cutting means (20), comprising horizontal rotating rollers (31, 32, 33) suitable for partially surrounding said winding shafts (4,4',4"), and for guiding the winding of the cut portion of the film (3) on said shafts, said winding shafts (4,4',4") being leaf expandable shafts comprising a plurality of circular sectors (62) moving radially with respect to the axis of the respective shaft (4,4',4").