Reinforcement Strand Loop Formation for Foamed Plastics
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Solution Overview
Problem
Current multi-needle systems for mechanical reinforcement of foamed plastics face challenges in producing reinforcement strand loops with precise dimensions and high clocking efficiency, especially when internal tension is high or reinforcement strands are sensitive, leading to difficulties in using a single strand for all needles.
Innovation Solution
A device with a rotatable profile body and integrated clamps and separating devices allows each needle to have its own reinforcement strand loop, featuring a compact and robust design for easy integration into existing systems, with a tensioning unit to manage strand tension and eccentrics for clamp actuation, enabling precise and efficient production of reinforcement strand loops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single reinforcement strand is used as a template for all needles, then the design effort is significantly reduced, but the process becomes unreliable when internal tension is too high, process times are too short, or the reinforcement strand is too sensitive
Solution Approach 1:
The invention divides the single reinforcement strand into multiple separate reinforcement strands, with each needle receiving its own individual strand. This segmentation allows each strand to be independently managed and formed into loops, eliminating the reliability issues caused by using a single shared strand under high tension or short process times, while maintaining design efficiency through the standardized loop formation mechanism.
2Reliability
If each needle has its own reinforcement strand loop, then process reliability is improved, but the device complexity and spatial requirements increase
Solution Approach 1:
The invention employs a universal loop formation mechanism that can process multiple reinforcement strands simultaneously through a standardized procedure. The device uses a common profile body, slide, and clamp system that works with each individual strand in the same manner, achieving high reliability through individual strand handling while avoiding excessive complexity through the application of a universal processing approach across all needles.
3Ease of operation
If a device is designed to be spatially compact and easily integrated, then ease of integration is improved, but the ability to provide individual loops for each needle with high clocking efficiency may be compromised
Solution Approach 1:
The invention combines multiple loop formation operations into a single integrated device that processes multiple reinforcement strands simultaneously. The profile body with multiple clamps and the slide mechanism work together in a unified structure to form loops for several needles at once, achieving high clocking efficiency through parallel processing while maintaining a compact design that can be easily integrated into existing multi-needle systems.
Data Source
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AI summary
A device for providing reinforcement strand loops for a multi-needle system for mechanically reinforcing a component made of a foamed plastics material, has a profile body, at least two clamps positioned on the periphery and/or end face of the profile body for fixing a reinforcement strand to the profile body, at least one slider which can be moved in parallel with a central longitudinal axis of the profile body to produce a reinforcement strand loop, at least two separators positioned in the periphery and/or end face of the profile body for separating the reinforcement strand loop from the reinforcement strand and a feeder for feeding the reinforcement strand loop. As a result, reinforcement strand loops can be produced with high precision and individually presented to the needles and/or grippers of a multi-needle system.