Web Winding Apparatus Air Ejection Core Attachment
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Solution Overview
Problem
Existing winding processes for web materials onto cores often require adhesive tape or hot melt adhesive, leading to waste, equipment jamming, and irregular roll formation, and do not allow for seamless core changes without stopping the process.
Innovation Solution
A winding apparatus that uses a crossbar with nozzles to eject compressed air, guiding the web material onto the core without adhesives, ensuring smooth contact and efficient core changes by creating an air cushion and controlled cutting, allowing for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape or hot melt adhesive is used to attach web material to the core, then the web material can be securely attached during winding, but waste is generated, equipment jamming occurs, and roll formation becomes irregular
Solution Approach 1:
The invention extracts and eliminates the adhesive tape or hot melt adhesive from the winding system. Instead of using adhesive to attach the web material to the core, the system uses a pair of synchronously rotating drums that mechanically guide and wrap the web material around the core through friction and controlled tension, completely removing the adhesive component and its associated waste problems
Solution Approach 2:
The invention replaces the chemical adhesion mechanism (adhesive tape or hot melt) with a mechanical system consisting of two synchronously rotating drums. These drums use controlled friction and mechanical guidance to attach and wind the web material onto the core without any adhesive, substituting chemical bonding with mechanical interaction
2Reliability
If adhesive tape is used to attach web material to the core, then the web can be attached during winding, but the tape is pulled off into the apparatus causing equipment damage or stoppage
Solution Approach 1:
The invention removes the adhesive tape entirely from the system, replacing it with a mechanical drum-based attachment system that uses controlled friction and tension to secure the web material to the core without any tape that could be pulled into the equipment and cause damage
Solution Approach 2:
The invention substitutes the tape-based mechanical attachment system with a dual-drum mechanical system that uses synchronized rotation and controlled friction to attach and wind the web material, eliminating the harmful effect of tape being pulled into the apparatus
3Reliability
If adhesive is used to attach web material to the core, then the web can be secured during winding, but the adhesive is absorbed into the web causing layers to stick together and become waste
Solution Approach 1:
The invention extracts the adhesive substance from the winding process and replaces it with a mechanical attachment method using synchronously rotating drums that secure the web material through controlled friction and tension, preventing adhesive absorption and subsequent web layer sticking
Solution Approach 2:
The invention replaces the chemical adhesion process with a mechanical system where two synchronously rotating drums guide and secure the web material onto the core through friction-based contact and controlled tension, eliminating the problem of adhesive absorption causing web layers to stick together
4Ease of operation
If core changes are performed by stopping the winding process, then the core can be replaced, but productivity is reduced due to process interruption
Solution Approach 1:
The invention prepares the next empty core in advance by positioning it near the winding drum while the current winding process continues. When the current core is full, the pre-positioned core is already ready for immediate transfer, eliminating the need to stop the winding process for core preparation and enabling seamless core changes
Solution Approach 2:
The invention maintains continuous winding operation by implementing a core transfer mechanism that operates concurrently with the winding process. The retainer arms and roller system enable core changes without interrupting the web material feed or winding drum rotation, ensuring the useful action of winding continues uninterrupted
5Manufacturing precision
If a roller lifts the web material from the winding drum during winding, then the web can be cut cleanly to create a free end, but the lifting mechanism adds device complexity
Solution Approach 1:
The invention merges the web lifting function with the existing retainer arms that are already part of the core transfer mechanism. The retainer arms incorporate rollers that perform the lifting function during the core transfer operation, combining two functions (core transfer and web lifting) into a single integrated mechanism, thereby reducing overall device complexity
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 the winding of web materials onto cores without adhesives, reducing waste and equipment jams, ensuring a smooth, high-quality roll with minimal disruption during core changes, and maintaining process continuity.
Implementation Method 1
By expelling a gas, preferably compressed air, onto the first side of the web material... the web material is lifted from the surface of the crossbar and when gas/air is ejected through the nozzles, the web material is forced away from the surface of the crossbar as a kind of air cushion is established between the crossbar and the web material
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention regards a winding apparatus (3) for winding a web material (2) onto an empty core (1) and into a roll (7). The winding apparatus (3) has a winding drum (6) for guiding the web material (2) by supporting the web material (2) on its first side (8). The winding apparatus (3) also has cutting means (15) for cross cutting the web material (2). The winding apparatus (3) further has nozzles (19) on a crossbar (11) for ejecting a gas onto the first side of the web material (8) near a free end of the web material (20). By ejecting a gas, preferably compressed air, onto the free end of the web (20), the free end (20) is blown towards the empty core (1) which is rotated. When the free end of the web material (20) comes into contact with the rotating empty core (1), due to the ejected gas/air, the web will easily be "caught" by the rotating empty core (1), even without tape or adhesive, and a new roll of web material (7) is wound.