Vertical Axis Winding Device for Cushioning Material
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Solution Overview
Problem
Existing systems for spiral-winding three-dimensional upholstery material from railway-shaped starting materials are inefficient, unsafe, and difficult to use, particularly due to complex handling and the need for frequent machine activation, which reduces productivity and increases the risk of injury.
Innovation Solution
A wrap device with a reel equipped with deflectors arranged symmetrically around an axis of rotation, allowing for safe and easy wrapping of the upholstery material into a spiral shape, which can be adapted for various surface shapes and sizes, including rectangular and square formats, and includes a housing for protection and efficient material handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a winding device with horizontal rotation axis and flights is used to spiral-wind cushioning material, then the cushioning material can be wound into a spiral shape, but the device becomes complicated to operate, unsafe, and reduces productivity due to frequent machine activation and difficult handling
Solution Approach 1:
The patent inverts the conventional horizontal rotation axis to a vertical rotation axis. This fundamental inversion changes the entire operating mechanism: the cushioning material is fed vertically downward under its own weight through a guide, and the vertical reel with radially extending drivers winds the material by rotating about the vertical axis. This eliminates the need for complex horizontal guide mechanisms and makes the device safer and more productive to operate
Solution Approach 2:
The patent extracts and eliminates the complex horizontal guide mechanism and scissor-like guide from the conventional winding device. By using a vertical rotation axis, the guide for directing cushioning material to the reel is simplified to a vertical guide that allows the material to feed downward under gravity, removing dangerous moving parts and complex activation mechanisms
2Reliability
If a winding device with horizontal rotation axis and scissor-like guide is used, then the cushioning material can be guided to the reel, but the risk of injury from moving parts increases significantly
Solution Approach 1:
By inverting the rotation axis from horizontal to vertical, the patent eliminates the scissor-like guide and other complex horizontal moving parts that pose safety risks. The vertical configuration allows the cushioning material to be guided simply by gravity feed through a vertical guide, removing dangerous mechanical components while maintaining reliable material delivery to the reel
3Productivity
If the winding device winds one coil at a time, then the cushioning material can be wound into coils, but the time required for packing increases and throughput decreases
Solution Approach 1:
The vertical reel configuration enables continuous winding operation without the need to stop and remove individual coils from horizontal flights. The cushioning material continuously feeds downward under gravity and is wound onto the rotating vertical reel, allowing for uninterrupted production and eliminating waiting time between coil formations
Solution Approach 2:
The vertical reel with radially extending drivers creates a dynamic winding system where the drivers can be positioned at various radial distances from the axis of rotation. This allows the reel to adapt to different cushioning material widths and winding diameters, enabling continuous operation with varying product specifications without manual reconfiguration
4Ease of operation
If the cushioning material spiral is tightly wound around horizontal flights, then the spiral shape is formed, but the inner coils stick to the flights and are difficult to remove
Solution Approach 1:
By inverting the rotation axis to vertical, the patent eliminates the horizontal flights that cause adhesion problems. The cushioning material is wound directly onto the vertical reel body or onto removable vertical cores, where gravity naturally pulls the wound material away from the reel surface, preventing sticking and making removal trivial when needed
5Adaptability or versatility
If the winding device is designed for circular spirals, then the cushioning material can be wound efficiently, but the adaptability to rectangular or square carton surfaces is reduced
Solution Approach 1:
The vertical reel with radially extending drivers creates a dynamically adjustable winding system. The drivers can be positioned at different radial distances from the axis of rotation, allowing the reel to wind cushioning material into spirals of varying diameters and shapes. This enables adaptation to rectangular or square carton surfaces by adjusting the driver positions to create non-circular spiral patterns that better fit angular container geometries
Data Source
Figure 1~3e
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AI summary
A winding device (1) for spirally winding a three-dimensional cushioning material (3) which is produced by a cushioning forming machine (5) from a web-type starting material, in particular from a roll or a concertina fold, for example of paper, the device comprising a coiler (11) with at least two deflector elements, such as mandrels (21, 21', 23, 23"), hooks (25), deflection edges (23*), or the like, and with an axis of rotation (D) extending in the vertical direction (V).