Rounded Turning Bars for Substrate Web Folding
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Solution Overview
Problem
Existing wrapping devices for forming tubular structures from substrate webs often damage the web or printed images due to sharp-edged folding devices, leading to risks of damage and image distortion.
Innovation Solution
A wrapping device using rounded surfaces for folding, with inlet and outlet turning bars arranged at specific angles to guide the substrate web in a way that only rounded surfaces come into contact, reducing friction and the risk of damage, and allowing for adjustable configurations to accommodate different web widths and overlaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sharp-edged folding devices (plow folds or folding plates) are used to fold the substrate web into a tube, then the folding process is simple and effective, but the substrate web and printed image are at risk of damage
Solution Approach 1:
The patent replaces sharp-edged folding devices with rounded turning bars that have curved surfaces. The substrate web is guided over these rounded surfaces, which distribute the folding stress across a larger area and eliminate concentrated pressure points that cause damage. This curvature principle directly resolves the contradiction by maintaining folding effectiveness while eliminating damage risk.
2Object-affected harmful factors
If rounded turning bars are used for folding the substrate web, then damage risk is reduced, but the device complexity increases due to multiple angled turning bars
Solution Approach 1:
The folding process is divided into multiple sequential stages, each handled by a specific turning bar (first inlet turning bar, second inlet turning bar, first outlet turning bar, second outlet turning bar). Each bar performs a portion of the folding action at a specific angle, breaking down the complex folding operation into manageable segments that collectively achieve the tubular formation without damaging the substrate.
Solution Approach 2:
The turning bars are arranged in three-dimensional space with specific angular relationships (angles α, β, δ, and φ relative to center plane and exit plane). This spatial arrangement allows the substrate web to be guided through a controlled three-dimensional path, transforming a potentially complex two-dimensional folding problem into a manageable three-dimensional guidance system.
3Manufacturing precision
If the wrapping device is configured for specific web widths, then folding precision is improved, but the adaptability to different web widths decreases
Solution Approach 1:
The patent makes the turning bars adjustable in their positions and angles. The first and second inlet turning bars can be adjusted relative to the center plane, and the outlet turning bars can be adjusted to change the exit plane orientation. This dynamic adjustability allows the device to adapt to different web widths while maintaining precise folding control, resolving the contradiction between fixed precision and variable adaptability.
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 minimizes damage to the substrate web and printed images by using rounded surfaces and adjustable configurations, ensuring low friction and enabling the formation of tubes with reduced risk of damage and improved flexibility for various web widths and overlaps.
Implementation Method 1
very low friction between the substrate web and the turning bars used is ensured
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a folding device (1) for folding a substrate web (6) entering in an infeed direction E on at least one side, comprising at least one first infeed turning bar (2-1) and at least one first outfeed turning bar (3-1). The invention is based on the objective of providing a solution that dispenses with sharp-edged folding devices and achieves folding of a substrate web (6) by means of rounded surfaces. This objective is achieved in that the first outfeed turning bar (3-1) describes an exit plane A of the exiting folded substrate web (6) and describes an angle ϕ to a median plane M, wherein the median plane M is perpendicular to the exit plane A and is aligned parallel to the infeed direction E, and wherein the first infeed turning bar (2-1), in projection onto the median plane M, forms an angle α with the exit plane A.and wherein the first inlet turning rod (2-1) forms an angle β perpendicular to the median plane M with respect to the outlet plane A, and wherein the first inlet turning rod (2-1) forms an angle δ with respect to the median plane M in projection onto the outlet plane A, and wherein the substrate path (6) with the area to be driven over can be guided over the first inlet turning rod (2-1), and wherein the substrate path (6) can be guided along the first outlet turning rod (3-1) such that the driven side of the substrate path (6) faces the first outlet turning rod (3-1).