Patent Application
20250026608
The present invention relates generally to an apparatus and method for winding a length of continuous, elongate, flexible material onto a spool and for retaining a free end of the material on the spool. In an embodiment, the invention is a spool for receiving a length of a continuous, elongate, flexible material wound onto the spool wherein the spool has a flange with a locking notch for retaining an outermost free end of the wound material on an outer periphery of the flange.
A generally cylindrical container having an axial through opening and a generally planar rim adjacent at least one end is commonly utilized for winding, storing and subsequently dispensing a length of a continuous, elongate, flexible media or the like. The container may be a reel, hub, bobbin, spindle, spool or the like, and is collectively referred to herein as a spool. The rim adjacent at least one end of the spool may be a collar, ridge, rib, flange or the like, and is collectively referred to herein as a flange. The continuous, elongate, flexible media or the like is typically a relatively thin or small diameter material, such as wire, fiber, rope, string, electrical cable, optical cable or filament. The material is wound onto the spool and stored on the spool, for example while being inventoried and during transport. By way of example and not limitation, the material wound onto the spool may be a three-dimensional (3D) printing filament that is wound onto the spool and subsequently dispensed from the spool for use in a production process, such as a 3D printing process. In some instances, the spool of wound material is provided with exterior packaging material, such as at least one layer of stretch wrap. The stretch wrap retains the outermost free end of the material wound onto the spool to prevent the wound material from unwinding and to protect the wound material from being damaged during storage or transport. The stretch wrap is subsequently removed to allow the wound material to be dispensed from the spool, for example to be used in a production process.
Winding equipment for winding a continuous, elongate, flexible material onto a spool is commonly known and is referred to herein as a spooler. The use of stretch wrap to retain the outermost free end of the wound material requires packaging equipment, namely, a stretch wrap applicator, in addition to the spooler. An example of a known spooler and stretch wrap applicator is shown and described in United States Patent Application Publication No. 2015/0360800 A1. The cost, size and complexity of the spooler is increased by the addition of the stretch wrap applicator and the stretch wrap, while at the same time the speed and efficiency of the spooling process is reduced. Furthermore, the stretch wrap must be removed before the wound material can be dispensed from the spool for use, likewise increasing the cost, while reducing the speed and efficiency of the corresponding production process. The stretch wrap removed from the spool is not reused and must be disposed or recycled. Consequently, it is not always necessary, or even desirable, to protect the wound material on the spool with stretch wrap. Nevertheless, it remains necessary, or at the least desirable, to retain the outermost free end of the material wound on the spool to prevent the wound material from unwinding from the spool prior to being dispensed from the spool for use in a production process.
In view of these shortcomings, problems, deficiencies and drawbacks, it is apparent that improved winding equipment is needed for winding a continuous, elongate, flexible material onto a spool and retaining an outermost free end of the wound material on the spool. A particular need exists for a spooler for winding a length of a continuous, elongate, flexible material onto a spool and for retaining the outermost free end of the wound material on the spool. A still further need exists for a spool that does not require a stretch wrap applicator and stretch wrap to retain the outermost free end of the wound material on the spool. Such a spooler and spool would reduce the cost, size and complexity of the spooler, while increasing the speed and efficiency of the spooling process and the subsequent production process. Furthermore, such a spooler and spool would obviate the need to remove the stretch wrap before dispensing the wound material from the spool. A further need exists for an automated spooler that provides the option to apply at least one layer of stretch wrap to material wound onto a spool, or alternatively, to retain an outermost free end of the wound material on the spool within a locking notch formed on an outer periphery of a flange of the spool.
The present invention addresses the shortcomings, problems, deficiencies and drawbacks associated with existing spoolers for winding a length of a continuous, elongate, flexible material onto a spool and retaining an outermost free end of the wound material on the spool. In particular, the present invention provides a significant improvement and advantage over existing winding equipment that utilizes a stretch wrap applicator and stretch wrap to retain an outermost free end of the material wound on the spool. In advantageous embodiments, the invention is an automated spooler, a spool having a flange with a locking notch and associated methods for winding a length of a continuous, elongate, flexible material onto the spool and for retaining an outermost free end of the wound material on an outer periphery of the flange.
In one aspect, the invention is embodied by a spooler for winding a length of a continuous, elongate, flexible material onto a spool. In an embodiment, the spooler is an automated spooler including a winding enclosure and a conveying unit configured and operable for automatically conveying an empty spool into the winding enclosure and for automatically conveying a spool of wound material out of the winding enclosure to a collection area. The automated spooler further includes an indexing unit within the winding enclosure configured and operable for automatically positioning a feed hole provided on the spool at a predetermined location for feeding the material to the spool. The automated spooler further includes a feeding unit within the winding enclosure configured and operable for automatically feeding an innermost free end of the material through the feed hole provided on the spool. The automated spooler further includes a spooling unit within the winding enclosure configured and operable for automatically gripping the innermost free end of the material and rotating the spool to wind the material onto the spool.
In an embodiment, the indexing unit includes at least one roller for rotating the spool on the indexing unit to position the feed hole at the predetermined location for feeding the material to the spool. The at least one roller may have at least one groove for receiving a flange provided on the spool adjacent an axial end of the spool.
In an embodiment, the feeding unit is disposed above the indexing unit with the feed hole positioned at the predetermined location for feeding the material to the spool. The feeding unit is movable downwardly in a vertical direction from a retracted position to an extended position for feeding an innermost free end of the material to the spool. The feeding unit includes a cam plate and an associated cam that guide and position a feed tube above the feed hole provided on the spool and positioned at the predetermined location for receiving the innermost free end of the material. The feed tube of the feeding unit is configured and operable for feeding the innermost free end of the material through the feed hole provided on the spool. In an embodiment, the feed hole defines an opening that extends through an elongate, cylindrical barrel of the spool on an interior side of a flange adjacent an axial end of the barrel of the spool.
In an embodiment, the spooling unit includes an attachment clamp configured and operable for gripping the innermost free end of the material within the barrel of the spool while the material is being wound onto the spool during the spooling process. The attachment clamp includes a pair of clamping pins disposed within the interior of the barrel of the spool that close together to grip the innermost free end of the material within the barrel of the spool. The spooling unit further includes a spool drive that is configured and operable for transferring rotational movement to the spool during the spooling process. The spool drive may have a resilient or rough covering, pad or the like that provides increased friction between the spool drive and the spool during the spooling process. The clamping pins of the attachment clamp protrudes outwardly in the axial direction from the spool drive to grip the innermost free end of the material within the barrel of the spool.
In an embodiment, the spool drive is movable in an axial direction and is biased in the axial direction by a biasing element. When a spool is loaded into the spooling unit, a flange of the spool is positioned against the spool drive and the biasing element is compressed behind the spool drive. The spool drive of the spooling unit rotates the spool during the spooling process while the feed tube of the feeding unit feeds the material to the spool. Upon completion of the spooling process, the material wound onto the spool is retained on the spool and a cutting unit cuts an outermost free end of the wound material. The attachment clamp then releases the innermost free end of the material within the barrel of the spool and the compressed biasing element of the spooling unit exerts a biasing force on the spool drive to move the spool of wound material in the axial direction away from the spool drive so that the spool of wound material can be conveyed by the conveying unit out of the winding enclosure to the collection area.
In another aspect, the invention is embodied by an automated spooler including an optional packaging unit configured and operable for automatically applying at least one layer of stretch wrap to a spool of wound material. In an embodiment, the packaging unit is an automated stretch wrap applicator including an applicator clamp. The applicator clamp is movable between an opened position and a closed position to grip the stretch wrap and is rotatable around the spool to cover the spool of wound material with at least one layer of stretch wrap. The stretch wrap applicator further includes a cam plate having a cam profile that controls when the applicator clamp is in the opened position and when the applicator clamp is in the closed position. In the closed position, a clamp plate of the applicator clamp is pressed against a stop with an end of the stretch wrap disposed between the clamp plate and the stop. The applicator clamp of the stretch wrap applicator further includes a cutting blade operable for automatically cutting the stretch wrap once the spool of wound material is packaged with at least one layer of stretch wrap. The stretch wrap applied to the spool of wound material by the optional packaging unit retains the outermost free end of the material on the spool and protects the wound material from damage during storage or transport.
In another aspect, the invention is embodied by a spool for receiving a length of a continuous, elongate, flexible material wound onto the spool wherein the spool has a flange with a locking notch for retaining an outermost free end of the wound material on the spool. The spool includes a barrel that extends in an axial direction and at least one flange that extends outwardly from the barrel of the spool in a generally radial direction. In an embodiment, the flange is disposed adjacent an axial end of the barrel and the locking notch is formed at an outer periphery of the flange to retain an outermost free end of the wound material on the spool. In an embodiment, the flange is configured as a substantially planar, relatively thin, generally cylindrical disk and the locking notch is disposed along the circumference of an outer peripheral edge or rim of the flange.
In an embodiment, the locking notch defines a receiving portion that extends from the outer periphery of the flange and a retaining portion that extends from the receiving portion. The receiving portion may be tapered inwardly from the outer periphery of the flange towards the retaining portion of the locking notch. Similarly, the retaining portion may be tapered inwardly from the receiving portion of the locking notch. In an embodiment, a transition region defining a relatively small radius may be disposed between the receiving portion and the retaining portion to facilitate a smooth transition of the material from the receiving portion into the retaining portion of the locking notch. In an embodiment, the receiving portion or the retaining portion may have a reduced cross-section area configured and operable for securing an outermost end of the wound material while the material is cut. In an advantageous embodiment, the receiving portion of the locking notch extends in a generally circumferential direction, while the retaining portion extends in a generally radial direction. In another advantageous embodiment, the receiving portion of the locking notch extends in a generally radial direction, while the retaining portion extends in a generally circumferential direction.
In another aspect, the invention is embodied by a method for winding a length of a continuous, elongate, flexible material onto a spool and retaining an outermost free end of the material on the spool. The method includes conveying an empty spool into a winding enclosure of a spooler. The method further includes indexing the empty spool to position a feed hole provided on a barrel of the spool at a predetermined location for feeding the material to the spool. The method further includes feeding an innermost free end of the material through the feed hole provided on the spool. In an embodiment, the feed hole defines an opening that extends in a generally radial direction through the barrel of the spool. The method further includes gripping the innermost free end of the material within an interior of the barrel of the spool. The method further includes rotating the spool to wind a length of the material onto the spool during a spooling process.
In an embodiment, indexing the empty spool to position the feed hole provided on the barrel of the spool includes rotating the spool on at least one roller having at least one groove for receiving a flange adjacent an axial end of the barrel of the spool. The groove of the roller restricts movement of the spool on the spooler in an axial direction while the spool is rotated to position the feed hole at the predetermined location for feeding the innermost free end of the material to the spool.
In an embodiment, the method further includes rotating the spool to wind a length of the elongate, flexible material onto the spool and cutting an outermost free end of the material wound onto the spool. The method further includes optionally packaging the material wound onto the spool by applying at least one layer of shrink wrap onto the wound material to thereby retain an outermost free end of the wound material on the spool and to prevent damage to the wound material during storage or transport.
In another embodiment, the method further includes rotating the spool to wind a length of the elongate, flexible material onto the spool. The method further includes optionally retaining an outermost free end a length of the elongate, flexible material wound onto the spool within a locking notch provided on an outer periphery of a flange of the spool and cutting the material with the outermost free end of the material secured within the locking notch provided on the flange.
In another aspect, the invention is embodied by a method for winding a length of a continuous, elongate, flexible material onto a spool having a flange with a locking notch and retaining an outermost free end of the material within the locking notch on the flange. In an embodiment, the spool includes a barrel that extends in an axial direction and the spool includes at least one flange adjacent an axial end of the barrel of the spool. The at least one flange extends outwardly from the barrel in a generally radial direction and the locking notch is provided on an outer periphery of the flange. In an embodiment, the flange is configured as a substantially planar, relatively thin, generally annular disk, and the locking notch is formed on an outer periphery, or outer circumference, of the flange for retaining the outermost free end of the wound material on the spool. In an embodiment, the locking notch includes a reduced cross-section area for securing the outermost free end of the wound material while the material is cut.
In yet another aspect, the invention is embodied by a spooler and a spool having a flange with a locking notch for retaining an outermost free end of a length of a continuous, elongate, flexible material on an outer periphery of the flange. The spooler includes a feeding unit that is movable in an axial direction and in a radial direction for feeding the material to the spool. The spooler further includes a spooling unit configured and operable for rotating the spool during a spooling process. The feeding unit includes a feed tube configured and operable for feeding the material to the spool as the spooling unit rotates the spool to wind the material onto the spool. With a desired length of the material wound onto the spool, the feeding unit is operable to move the feed tube in the axial direction beyond an exterior surface of the flange of the spool.
In an embodiment, the spooling unit is operable to rotate the spool such that the locking notch is positioned at a predetermined location relative to the material extending from the feed tube and the material is retained within the locking notch provided on the outer periphery of the flange. The spooler further includes a cutting unit operable for cutting the material with an outermost free end of the material secured within the locking notch on the spool.
In another embodiment, the spooling unit is operable to rotate the spool such that the locking notch is positioned at a predetermined location relative to the material extending from the feed tube. The feeding unit is then operable to move the feed tube and the material inwardly in the radial direction such that the material is received within the locking notch on the outer periphery of the flange. The spooling unit is operable to further rotate the spool such that the material extending from the feeding tube is retained within the locking notch provided on the outer periphery of the flange. The spooler further includes a cutting unit operable for cutting the material with an outermost free end of the material secured within the locking notch on the spool.
In an embodiment, the flange is configured as a substantially planar, relatively thin, generally annular disk and the locking notch of the flange is formed on an outer periphery of the flange, or on an outer circumferential edge or rim of the flange. The spooler may further include an indexing unit configured and operable to position the locking notch on the flange at a predetermined location relative to the material extending from a feed tube. The material extending from the feed tube is received and retained within the locking notch when the spool is rotated. Alternatively, the material extending from the feed tube is received within the locking notch when the feed tube is moved inwardly in the radial direction and the material is retained within the locking notch when the spool is rotated in the circumferential direction. The material is then cut with an outermost free end of the material secured within the locking notch on the spool.
In an embodiment, the locking notch is formed in an outer circumferential edge or rim of the flange and includes a receiving portion that extends from the outer periphery of the flange to a receiving portion. In an embodiment, the receiving portion extends in a generally circumferential direction and the retaining portion extends in a generally radial direction to retain an outermost free end of the wound material on the spool within the locking notch. In another embodiment, the receiving portion extends in a generally radial direction and the retaining portion extends in a generally circumferential direction to retain an outermost free end of the wound material on the spool within the locking notch. The receiving portion or the retaining portion of the locking notch may have a reduced cross-section area for securing the outermost free end of the wound material on the spool while the material is cut.
In an embodiment, the spooler further includes a packaging unit having a stretch wrap applicator for packaging the material wound on the spool with at least one layer of a stretch wrap so that an outermost free end of the wound material is retained on the spool. The spooler further includes a controller unit operable for determining whether to activate the stretch wrap applicator to package the wound material on the spool with the at least one layer of stretch wrap, or alternatively, to retain the outermost free end of the wound material within a locking notch provided on an outer periphery of a flange of the spool.
Referring now to the accompanying drawings, in which like reference characters refer generally to the same or similar parts,
In a particularly advantageous aspect of the invention, the spooler is an automated spooler and the material is a plastic filament, referred to as three-dimensional (3D) printing filament, that is useful in a three-dimensional (3D) printing process or production. The 3D printing filament may be formed by an extrusion production and wound onto a spool by the automated filament spooler. The spool of wound filament may optionally be packaged with a stretch wrap material to retain the wound filament on the spool during storage and transport until the filament is subsequently dispensed from the spool for use in the 3D printing process or production. Alternatively, according to another aspect of the invention, the outermost free end of the wound filament may be retained on a spool having a flange with a locking notch. Persons having ordinary skill in the art will readily understand and appreciate that the spool is manufactured independent of the material to be wound onto the spool, except that the construction of the spool, including without limitation its materials, dimensions, geometry, reinforcement elements, etc., may be influenced by the type of material. Furthermore, the automated spooler and/or spool of the invention may be utilized with other materials and other types of filaments, as well as in various other applications without departing from the scope of this disclosure.
The exemplary embodiments of a spooler shown and described herein are configured for use with continuous, elongate, flexible material, including by way of example and without limitation, 3D printing filament, having any desired cross-sectional shape (e.g., round, square, rectangular) or size. Regardless, it is intended that the invention be interpreted and construed broadly to encompass spoolers configured for automatically winding continuous, elongate, relatively thin or small diameter, flexible material onto spools, reels, hubs and the like, as well as other suitable articles of manufacture, collectively referred to herein as a spool, and for retaining the wound material on the spool, without unreasonable exception or alteration.
In
Importantly, the empty spools 52 are conveyed on conveyor 54 from the intake side 51 into the spooler 50 and the wound spools 52′ are conveyed on conveyor 54 from the spooler 50 in an automated manner. Consequently, an operator is not required to manually load an empty spool 52 onto a spooling head or to manually remove a wound spool 52′ from a spooling head. The spooler 50 further comprises a frame 55 having an enclosure 56 that defines an interior, safety covers 57 disposed over portions of the conveyor 54, and a lockable safety panel or door 58 for limiting access to the components of the spooler 50 within the interior of the enclosure 56. As a result, the automated spooler 50 is faster, more accurate, more efficient, and safer than a manual spooler.
Generally speaking, an empty spool 52 is conveyed on the conveyor 54 into the enclosure 56 from the intake side 51 of the automated spooler 50. The empty spool 52 is then indexed to position a feed hole provided on the spool 52 at a predetermined location for feeding the material to the spool 52. The properly indexed empty spool 52 is then releasably received on a spooling head. Next, a feeding unit automatically feeds an innermost free end of a continuous, elongate, flexible material to be wound onto the spool 52 through the feed hole provided on the spool 52. The spooling head of the spooler 50 automatically grips the innermost free end of the material received within the interior of the spool 52 through the feed hole. The spooling head of spooler 50 then automatically winds a predetermined length of the material onto the spool 52 and an outermost free end of the length of the material wound onto the spool 52 is cut to produce the wound spool 52′.
The automated spooler 50 next may optionally cover the material on the wound spool 52′ with packaging, and in particular, with at least one layer of a stretch wrap. The remaining stretch wrap is then cut from the wound spool 52′. The wound spool 52′ is then released from the spooling head and automatically conveyed on conveyor 54 out of the enclosure 56 of the spooler 50 to the outtake side 53 of the spooler 50. If desired, the spooler 50 may further comprise an optional automated fault detector (not shown) for detecting a possible fault in the material wound onto the spool 52′ or a possible fault with the spool. In the event of a detected fault, the wound spool 52′ is ejected from the conveyor 54 into a recycle bin for salvaging the wound material and/or the spool. Wound spools 52′ without a detected fault accumulate in the collection area at the end of the conveyor 54 on the outtake side 53 of the automated spooler 50 to be removed by an operator.
Specific operational components of the automated spooler 50 will now be described in greater detail with reference to
The feed hole 62 defines a relatively small opening for receiving the free end of the filament relative to the elongate width of the barrel 61 of the empty spool 52. Consequently, the empty spool 52 must be accurately positioned on the rollers 64 of the indexing unit 60. Otherwise, an indexing sensor beam (not shown) of the indexing unit 60 will not be able to detect the feed hole 62 on the barrel 61 of the empty spool 52. At least one groove 66 is provided on at least one of the rollers 64 of the indexing unit 60 for receiving an end flange 63 of the empty spool 52. With an end flange 63 disposed within groove 66 of the indexing unit 60, the spool 52 will not move (i.e. slide) laterally on the rollers 64 in an axial direction X when the rollers 64 rotate to position the feed hole 62 at the location necessary for receiving the free end of the filament.
The spool drive flange 82 on the spooling head 81 of the spooling unit 80 is configured and operable for transferring rotational movement to the spool 52 during the spooling (winding) process. In a preferred embodiment, the spool drive flange 82 may have a covering 83 that provides increased or enhanced friction between the spool drive flange 82 and the spool 52 during the spooling process. The covering 83 may, by way of example and not limitation, be formed of an elastic material, such as rubber, hardened foam or the like. Regardless, spool drive flange 82 is movable in the axial direction X and biased by a biasing element, for example but without limitation, a compressible elastic spring. When the empty spool 52 is loaded into the spooling unit 80, a flange 63 of the spool 52 presses against the movable spool drive flange 82 and the biasing element is compressed behind the spool drive flange 82. As a result, the pair of pins of the filament end attachment clamp 84 protrude outwardly in the axial direction X from the spool drive flange 82 (see
The stretch wrap applicator 90 of automated spooler 50 comprises a cam plate 94 having a cam profile that controls when the clamp 92 is opened or closed.
As shown and described herein, spool 100 includes the barrel 104 extending in the axial direction X and a pair of flanges 102 that each extends outwardly from the barrel 104 of the spool 100 in a generally radial direction. Flanges 102 are each disposed adjacent an axial end of the barrel 104 and the locking notch 110 is formed at an outer periphery of each flange 102. In this manner, the spool 100 may be provided to a manual winding machine (commonly referred to as a winder) or to the automated spooler 50 of the present invention and wound in either orientation (i.e., left-to-right or right-to-left) to retain the outermost free end of the wound material on the spool 100. In an embodiment, each flange 102 is configured as a substantially planar, relatively thin, generally cylindrical disk and the locking notch 110 is disposed along the circumference of an outer peripheral edge or rim 106 of the flange 102. If desired, the barrel 104 of the spool 100 may further be provided with the feed hole 62 previously shown and described with respect to the automated spooler 50.
In an embodiment, the locking notch 110 defines a receiving portion 112 that extends from the outer periphery of the flange 102 and a retaining portion 114 that extends from the receiving portion 112. The receiving portion 112 may be tapered inwardly from the outer periphery of the flange 102 towards the retaining portion 114 of the locking notch 110 such that the locking notch 110 narrows in cross-sectional area from the outer periphery of the flange 102 to the receiving portion 112. Similarly, the retaining portion 114 may be tapered inwardly from the receiving portion 112 of the locking notch 110 such that the locking notch 110 narrows in cross-sectional area from the receiving portion 112 to the retaining portion 114. In an embodiment, a transition region 116 defining a relatively small cross-sectional radius may be disposed between the receiving portion 112 and the retaining portion 114 to facilitate a smooth transition of the material from the receiving portion 112 into the retaining portion 114 of the locking notch 110. In an embodiment, the receiving portion 112 or the retaining portion 114 of the locking notch 110 may have a reduced cross-section area configured and operable for securing the outermost end of the wound material on the flange 102 of the spool 100 while the material is cut.
By way of example and not limitation,
The foregoing description in conjunction with the accompanying drawing figures has disclosed one or more exemplary embodiments of an automated spooler for winding and optionally packaging a predetermined length of a continuous, elongate, flexible material, such as a three-dimensional (3D) printing filament for use in a three-dimensional (3D) printing production. In exemplary embodiments, the automated spooler includes an indexing unit configured and operable for positioning a feed hole of an empty spool at a location for receiving an innermost free end of the material within a barrel of the spool. The automated spooler further includes a feeding unit configured and operable for feeding the material to the spool. The automated spooler further includes a spooling unit with a spooling head having a biased spool drive flange and a movable attachment clamp configured and operable for gripping the innermost free end of the material through the feed hole of the spool. The automated spooler further includes an optional packaging unit (e.g., stretch wrap applicator) configured and operable for applying a packaging material, such as at least one layer of a stretch wrap, over the material on the wound spool.
The foregoing description in conjunction with the accompanying drawing figures has also disclosed one or more exemplary embodiments of a spool having at least one flange with a locking notch for securing an outermost free end of a length of a continuous, elongate, flexible material, such as a three-dimensional (3D) printing filament for use in a three-dimensional (3D) printing production. The locking notch includes a receiving portion for receiving the outermost end of the material and a retaining portion for retaining the outermost end of the material within the locking notch. The locking notch may further include a transition region disposed between the receiving portion and the retaining portion. The receiving portion of the locking notch or the retaining portion of the locking notch may have a reduced cross-section area for securing the outermost free end of the material within the locking notch. In any event, the spool having a flange with a locking notch obviates the need for providing an optional stretch wrap applicator on a spooler to reduce the complexity and cost, while increasing the efficiency of the spooler.
While exemplary embodiments of the invention have been described and shown in the accompanying drawing figures, those of ordinary skill in the art will readily acknowledge and appreciate that the apparatus, systems and methods of the present invention(s) may be embodied in numerous other forms and manners without departing from the broad intended scope of this disclosure. Accordingly, it is to be understood that this disclosure and any appended claims are to be interpreted given their broadest reasonable interpretation consistent with the forgoing written description and the accompanying drawings.
