Continuous Tubular Element Wrapping with Localized Web Gluing
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Solution Overview
Problem
Existing machines for producing continuous tubular elements with inner fillings face challenges in joining the outer and inner webs, limiting product variety and often result in suboptimal filtering or cooling functions due to the requirement for the filling to match the tubular element's cross-section.
Innovation Solution
A machine and method that shape and join continuous webs to form a tubular element with a spacer and/or filter function, allowing for shape stability and flexibility in the inner insert, using pre-forming rollers, guide bars, and precise gluing to maintain the desired configuration during wrapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the filling insert fills the tubular element completely (matching cross-section), then the wrapping operation can be performed, but the product variety is limited and the filtering/cooling function is compromised
Solution Approach 1:
The outer web is provided with adhesive application zones that are localized to specific areas rather than covering the entire surface. This allows the outer web to adhere to the filling insert at discrete contact lines or surfaces, rather than requiring complete cross-sectional matching. The adhesive is applied in specific regions to create secure bonding while allowing the filling insert to have a different overall shape and cross-section than the tubular element.
Solution Approach 2:
The adhesive bonding is segmented into discrete contact lines or surfaces rather than a continuous bond across the entire cross-section. The outer web and filling insert are joined at specific localized zones along the longitudinal axis, allowing flexibility in the filling insert shape while maintaining structural integrity through distributed adhesive contact points.
2Productivity
If continuous webs are used for production, then productivity increases, but the joining of outer and inner webs becomes complex
Solution Approach 1:
The adhesive application system is integrated into the wrapping operation itself, where the adhesive is applied to the outer web and then the filling insert is wrapped around it in a continuous motion. The system uses the wrapping motion to simultaneously position and bond the components, eliminating the need for separate joining operations and reducing overall process complexity.
Solution Approach 2:
The adhesive is applied to the outer web before the filling insert is wrapped around it. This preliminary adhesive application allows the subsequent wrapping operation to proceed smoothly with automatic bonding, as the adhesive is already in position to receive the filling insert, eliminating the need for complex alignment and bonding operations during or after wrapping.
3Ease of operation
If discrete sheets are used for manual production, then ease of manual operation is maintained, but productivity is very low
Solution Approach 1:
The invention uses continuous webs for both the outer tubular element and the filling insert, allowing the production process to proceed without interruption. The adhesive bonding and wrapping operations occur in continuous motion along the longitudinal axis, eliminating the stop-start nature of discrete sheet processing and enabling sustained high-speed production while maintaining operational simplicity through automated adhesive application and wrapping.
Data Source
AI summary
A machine for making a continuous tubular element with filling from web material, including first and second means for feeding respective continuous webs, a forming station configured to perform a folding and/or deformation of a first continuous web in a shaped configuration, and a wrapping station wherein the second continuous web is wound in a tubular shape around the first continuous shaped web to obtain the continuous tubular element. Upstream of the wrapping station there is a first gluing device configured to apply at least one longitudinal line of glue on at least one of the continuous webs in such a way as to define at least one gluing zone, said longitudinal line of glue being positioned in such a way as to coincide with a zone of superposing and contact between the two continuous webs feeding out of the wrapping station.