Thread Bundle Forming with Movable Mold Segments
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Solution Overview
Problem
Existing methods for wrapping semipermeable hollow threads into circular bundles for filter devices are labor-intensive, prone to errors, and unsuitable for varying bundle diameters, leading to limited packing density and mechanical stress issues, which can result in premature wear and fatigue fractures.
Innovation Solution
A device with movable mold segments that form a closed polyline to encase threads into a circular cross-section, allowing for varying bundle diameters without mechanical retooling, and using vibrations to achieve higher packing density without film buckling, enabling fully automatic processing with minimal mechanical and control effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a linear reel with two support arms is used to automate coiling, then automation is improved, but the risk of thread damage from mechanical stress increases
Solution Approach 1:
The patent employs a polygonal reel with multiple support arms that rotate to collect threads, creating a dynamic system where the reel configuration changes during operation. The support arms are distributed around the circumference and can be adjusted, allowing the system to adapt to different thread bundle sizes while maintaining automated operation and reducing mechanical stress on individual threads.
2Manufacturing precision
If stronger compression is applied during foil wrapping to increase packing density, then filter performance is improved, but the risk of film buckling due to friction increases
Solution Approach 1:
The patent incorporates a vibration mechanism that acts on the foil during the wrapping process. The vibrations reduce friction between the foil and the thread bundle, allowing stronger compression to be applied without causing film buckling. This enables higher packing density to be achieved while maintaining film integrity throughout the wrapping process.
3Extent of automation
If open flexible channels with overlapping film edges are used for wrapping, then automation is improved, but the device complexity increases due to drive and control requirements
Solution Approach 1:
The patent uses a flexible foil that is wrapped around the thread bundle in a continuous motion. The foil's flexibility allows it to conform to the bundle shape and be sealed at the edges without requiring complex mechanical structures. This approach achieves automated wrapping with simpler drive and control systems compared to rigid channel-based solutions.
4Adaptability or versatility
If the reel configuration is changed to accommodate different bundle diameters, then adaptability is improved, but production stops occur requiring retooling
Solution Approach 1:
The patent designs the polygonal reel with multiple support arms that can be adjusted in position and number. This universal configuration allows the same reel to handle thread bundles of various diameters without requiring physical retooling or production stops. The system maintains adaptability across different product specifications while continuing uninterrupted production.
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 fully automatic production of bundles with higher packing density and compact design, suitable for a wide range of diameters, reducing the risk of thread damage and mechanical stress, and allowing operation on both linear and polygon reels without mechanical reconfiguration.
Implementation Method 1
By positioning the individual shape segments separately, the film (40) is guided in such a way that it completely encloses the irregularly shaped thread strand (41) without pinching individual threads in the overlapping edge areas.
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3~4
AI summary
The invention relates to a device and method for producing thread bundles to wind a foil (40) around a strand (41) which consists of a plurality of individual threads and has an irregular cross-section, and to form the strand to circular bundles, in particular for the production of dialysis filters.