Stationary Winding Frame for High-Speed Pile Article Production

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Solution Overview

Problem

Existing methods for manufacturing pile articles, such as weatherseals and brushes, are limited by slow production rates due to vibration-induced constraints in scotch yoke mechanisms and require slitting of continuous loops for removal from the winding frame.

Innovation Solution

The use of ultrasonic energy for welding and a stationary winding frame supported by mechanical, fluid pressure, or electromagnetic means allows for faster production rates and continuous loop formation without slitting, using ultrasonically weldable materials and wire loops to facilitate easy removal and resilient arch or bow configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If scotch yoke mechanism is used to support the winding frame, then the frame can be reciprocated to enable winding, but vibration limits the reciprocation speed and production rate

Engineering Contradiction:

Improveproduction rateVSAvoidvibration-induced speed limitation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces the mechanical scotch yoke mechanism with a stationary winding frame supported by electromagnetic means. This substitution eliminates the mechanical vibration problems inherent in reciprocating mechanisms, allowing for higher winding speeds and improved production rates without the reliability constraints of mechanical reciprocation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transitions from a static or reciprocating frame support system to a dynamically controlled electromagnetic support system. The electromagnetic means can rapidly adjust and maintain the frame in a stationary position during high-speed winding, providing the flexibility and stability needed for improved productivity without vibration limitations.

Inventive Principle:

Principle #15Dynamics

2Productivity

If continuous loops are wound on the frame, then production rate increases, but the loops must be slitted for removal from the apparatus

Engineering Contradiction:

Improveproduction rateVSAvoidremoval process complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent divides the continuous loop into segments that can be independently managed. The loops are wound continuously on the stationary frame at high speed, then selectively removed in controlled segments without requiring slitting. This segmentation approach maintains the productivity benefits of continuous winding while simplifying the removal process through targeted segment extraction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent prepares the continuous loops for easy removal by incorporating release mechanisms or design features during the winding process itself. The loops are pre-configured with characteristics that facilitate their subsequent removal without slitting, such as integrated release points or geometric features that allow clean detachment from the frame.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If ultrasonic welding is used to bind loop ends, then production rate increases and material versatility improves, but energy consumption increases

Engineering Contradiction:

Improveproduction rateVSAvoidultrasonic energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent employs periodic or intermittent ultrasonic welding cycles rather than continuous energy application. The ultrasonic welding heads operate in controlled cycles, activating only when needed to bind loop ends, which maintains high production rates while reducing overall energy consumption through pulsed rather than continuous operation.

Inventive Principle:

Principle #19Periodic action

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

Enables high-speed production of continuous loop pile articles that can be easily removed and configured as resilient supports or seals without slitting, enhancing production efficiency and versatility.

Implementation Method 1

The application of such energy facilitates the use of ultrasonic weldable material such as plastic monofilaments (preferably of the same material as the yarn) to provide the winding frame. Such filaments, and if desired a backing strip, may be welded together with the yarn loops at the ends of the loops, preferably with the aide of ultrasonic welding heads.

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

The support is maintained stationary, preferably by mechanical, fluid pressure operated (pneumatic or hydraulic) or electromagnetic means provided by the invention.

Methodology Applied

Scientific EffectElectromagnetic support: Electromagnet

Data Source

PatentUS7824513B2Apparatus and method for making pile articles and improved pile articles made therewith

Publication Date: 2010.11.02 ULTRAFAB INC

AI summary

Filamentary materials, such as yarn (18), is wound a frame (28), provided by pairs of movable filaments or wires (35, 38), about which the end of the spindle (22) rotates provides the turns (26) of the winding as the article having the winding is moved along a process path. Mechanically or hydraulically actuated pins (34) support the winding frame in a fixed position. The filaments of the frame may be provided by laterally spaced pairs (44, 46) of filaments of weldable material.