NL2014638B1 - Wrapping station, stuffing machine, method for wrapping. - Google Patents

Abstract

Wrapping station for wrapping a mat around a product, wherein the wrapping station is arranged for receiving the mat and the product in a longitudinal direction thereof, wherein the wrapping station comprises two lateral sides that are inclining upwardly towards a top side of the wrapping station, such that during movement of the product and the mat with respect to the wrapping station the mat is wrapped around the product by simultaneous contact with the lateral sides.

Description

Title: Wrapping station, stuffing machine, method for wrapping

The invention relates to a method and station for wrapping a mat around a product.

Typically, such stations are used for wrapping a soft mat around a ceramic substrate, as is for example the case for a catalyst. Also, such a wrapping station may be part of a larger installation such as a stuffing machine or the like.

In conventional wrapping stations, the soft mat is wrapped around the substrate by means of complex arms and fingers, requiring a lot of parts, actuators and coordination to keep the mat around the substrate. Alternatively, the mat is wrapped manually around the substrate. Once the mat is wrapped around the substrate, the wrapped substrate may be pushed into a funnel to compress the mat towards the substrate. Thereto, it is important that the mat remains wrapped around the substrate and does not accidentally folds open again. In case of manual wrapping, the mat is often closed by means of an adhesive tape. In case of an automated wrapping station, the coordination between the arms and fingers is rather complex to keep the mat closed until it is being pushed into the funnel. Wrapping a mat around a product is also applicable to other products than a substrate. A drawback of the manual method is that it requires human intervention and the possibility on mistakes is relatively large, e.g. the mat might loosen or may wrinkle or may tear etc. A drawback of the conventional automated station is that the arms, fingers, actuators etc. require relatively large space, are relatively complex and rather failure sensitive. Also for the conventional automated station, it is often a challenge to keep the mat closed while the mat and product is being pushed into the funnel. Further, when pushing the mat and product into the funnel, there is a risk that the mat might tear.

Therefore, there is a need for a wrapping station that can be automated, that may be less complex etc.

It is an object of the invention to provide for a wrapping station and/or a wrapping method that obviates at least one of the above mentioned drawbacks.

Thereto, the invention provides for a method for wrapping a mat around a product, comprising providing a wrapping station, positioning the mat and the product at an entrance of the wrapping station, moving the product with the mat, and the wrapping station, with respect to each other in a longitudinal direction of the wrapping station; whereby the mat is being wrapped around the product due to contact with the wrapping station while simultaneously the mat and the product are moved with respect to the wrapping station.

By moving the mat and product with respect to the wrapping station, the mat can be gradually folded around the product. This is contrary to the prior art manual and/or automated wrapping stations in which the product is kept stationary when the mat is being folded around it. Then, in the prior art systems, the wrapped product is being transported to the next station, typically a compressing station.

The mat can be made of a variety on compressible and/or flexible materials, such as metal and/or composite fibers and/or natural, such as wooden or cotton, fibers, it can be sponge-like material, or a rubber-like material, or a cloth, or a fabric, etc. Many variants of the mat are possible.

The product can be made of a variety of materials, such as ceramic, or composite, or metal and/or combinations thereof. Also, the product can be made by means of various techniques, such as molding, casting, extruding, etc. Advantageously, the product has a longitudinal axis along which the product extends. Further, the shape and/or size of the cross-section of the product may remain approximately the same or similar along the longitudinal axis of the product. Alternatively, the shape and/or size of the cross-section of the product may vary somewhat along the longitudinal axis of the product. For example, the cross-sectional shape may be polygonal or circular or elliptical etc. and may remain the same along the longitudinal axis of the product, while the size of the cross-section may increase or decrease somewhat along the longitudinal axis of the product to give the product a frusto-conical shape. Many variants are possible.

According to the invention the product with the mat and the wrapping station are being moved with respect to each other such that during the movement the mat is folded around the product by contact with the wrapping station. It is understood that the wrapping station may be stationary while the mat and product are moving. Alternatively, the mat and product can be stationary while the wrapping station is moving. In another embodiment, the product with the mat can move in one direction, while the wrapping station can move in the opposite direction. The wrapping according to the method of the invention can be done manually as well as automated.

Moving of the product and the mat can be done in various ways, for example a pusher can be used to push the product with the mat through the wrapping station, alternatively a puller can be used. Alternatively, a conveyor belt can be used on which the product with the mat are positioned and that conveys the product with the mat through or in the wrapping station. The movement can also be done manually, or by means of gripping arms that displace the product with the mat in or through the wrapping station. Alternatively, the wrapping station can be moved with respect to the product with the mat, for example by using rails on which the wrapping station is mounted or by pushing/pulhng the wrapping station, or even by self-propelling of the wrapping station. Many variants are possible to move the product with the mat and/or the wrapping station.

Due to the mat and product moving with respect to the wrapping station simultaneously with contacting of the mat by the wrapping station, the mat is being folded around the product. The wrapping station can be e.g. a funnel of which a cross-section at an entrance is larger than a cross-section at an end of the funnel where the mat and product are more inside of the funnel, or a tunnel having approximately the same cross-sectional size along the longitudinal axis. Before wrapping, the mat typically is laid underneath the product and extends sideways, then the mat and product can be positioned in or in front of the wrapping station, e.g. a tunnel, and they can be pushed through the tunnel. During movement of the mat and product through the tunnel, the mat is in contact with the tunnel walls, and due to the inclining slope of the tunnel walls, the mat can be folded around the product.

Advantageously, the wrapping station has a cross-sectional shape that mates and/or corresponds with the cross-sectional shape of the product, such that when moving the mat and product in the wrapping station, the shape of the product mates and/or corresponds with the shape of the wrapping station so the mat can be more easily and/or more tight-fitting wrapped around the product.

In a preferred embodiment, the wrapping station has lateral side walls that incline upwardly towards a top side of the wrapping station. The lateral sides thus may be upwardly sloping from an entrance opening of the wrapping station. The lateral sides may converge towards each other, but when reaching the top side, the lateral sides may or may not contact each other and there may still some space inbetween both sides. When the wrapping station has lateral side walls sloping upwardly, typically the wrapping station may be open to a top side thereof between the lateral sides. The open top side may then be partially closed by the upwardly sloping lateral sides. As such, a low maintenance wrapping station can be obtained, in particular in the stationary embodiment, since then very few movable components are present on the wrapping station. Thus, the wrapping station can easily be exchanged and replaced by another wrapping station, for example for a product with a different cross-section and/or diameter, or for example due to wear at the inner side of the wrapping station in view of the abrasive character of some of the mat materials.

Advantageously, the wrapping station may be embodied as a tunnel, at an entrance of the wrapping station, the wrapping station has lateral sides inbetween the mat and product may fit. The lateral sides advantageously have a limited height at the entrance of the wrapping station and then may gradually slope upwardly towards each other and towards a top side of the tunnel or funnel. Then when pushing the mat and product through the wrapping station; and/or vice versa, the mat is in contact with the lateral sides and is being folded around the product. Preferably, the wrapping station has a shape that is mating with the outer shape of the product to better fold the mat around the product. By providing a mating shape, the mat and product can be more easily enclosed by the wrapping station, and, in particular when the wrapping station is a funnel, the folding of the mat around the product may be done more easy and/or the mat may be folded around more tight-fitting to the product, which may be advantageous for a possible next step in the process of stuffing a mat-wrapped product into a shell.

In an advantageous embodiment,

The invention further relates to a method for inserting a mat-wrapped product into a shell, to a wrapping station for wrapping a mat around a product and to a machine comprising such a wrapping station.

Further advantageous embodiments are represented in the subclaims.

The invention will further be elucidated on the basis of exemplary embodiments which are represented in a drawing. The exemplary embodiments are given by way of non-hmitative illustration.

In the drawing:

Fig. 1 shows a schematic perspective view of a first embodiment of a wrapping station;

Fig. 2a shows a schematic perspective view of a second embodiment of a wrapping station;

Fig. 2b shows a side view of the wrapping station indicating the inclination angle;

Fig. 3a shows a top view of the product and mat with the pusher;

Fig. 3b shows a side view of the pusher adjacent the mat and the product;

Fig. 4 shows a schematic perspective view of a third embodiment of a wrapping station;

Fig. 5 shows a schematic perspective view of an embodiment of a stuffing machine; and

Figs. 6a - 6h show subsequent steps of wrapping a mat around a product and stuffing a mat-wrapped product into a shell.

It is noted that the figures are only schematic representations of embodiments of the invention that are given by way of non-limiting example. In the figures, the same or corresponding parts are designated with the same reference numerals.

Figure 1 shows a schematic embodiment of a wrapping station 1 for wrapping a mat 2 around a product 3. The product 3 can be made from different materials, such as a metal, or plastics, or a composite material, or a ceramic material or combinations thereof. Also, the product 3 may have various shapes, such as a tubular shape, or a cylindrical shape, or a conical shape, or a pyramidal shape, or a three dimensional spiral shape, etc. The product typically has a longitudinal axis A along which the product 3 extends. Perpendicular to the longitudinal axis A, the product 3 may have a cross-section which may vary in shape and/or size along the longitudinal axis A. The size of the cross-section may for example decrease somewhat along the longitudinal axis. The cross-section may have various shapes, such as circular, or elliptical, or polygonal, or a more organic shape etc.

The mat 2 is preferably flexible and/or compressible. For the wrapping around the product the mat is preferably flexible such that it can actually be folded around the product. In an embodiment, the mat is wrapped around the product in a wrapping station, then compressed in a compression station and inserted into a relatively rigid shell in a shell station, thereto the mat is preferably compressible such that the size of the cross-section can be reduced before providing the shell around the mat-wrapped product. The mat can be made of various materials, such as fibrous materials, or plastic material, or rubber material, or metal material such as metal filaments, or organic materials etc. The mat can be a cloth, or a textile, or a molded product, etc. Many variants are possible.

Advantageously, the wrapping station 1 has a cross-sectional shape that mates with the cross-sectional shape of the product 3, such that the mat 2 can be tightly closed around the product 3. In the embodiment of figure 1, the wrapping station 1 and the product 3 both have a rectangular cross-section, but other shapes, such as circular or elliptical may be possible.

The wrapping station 1 has a longitudinal direction extending along the longitudinal axis B. Advantageously, the product 3 and the mat 2 are positioned in or in front of the wrapping station 1 with the longitudinal axis A of the product 3 in the same direction as the longitudinal axis B of the wrapping station 1. The product 3 with the mat 2 can be moved with respect to the wrapping station 1 along the longitudinal axis B thereof in the direction C from an inlet li to an outlet lo.

The product 3 with the mat 2 can be moved through the wrapping station 1, for example by using a pusher that pushes the product 3 with the mat 2 through the wrapping station 1. Alternatively, a conveyor may be provided on which the product 3 with the mat 2 may be positioned or the wrapping station 1 may be positioned to be conveyed in longitudinal direction B. Also, the wrapping station 1 may be moved, for example over rails, while the product 3 with the mat 2 remains stationary. In the embodiment of figure 1, the movement means are not shown, but there are many variants possible to move the product with the mat and/or the wrapping station.

The wrapping station 1 is here provided with two lateral sides 4, 5 that are inclining upwardly towards a top side 6 of the wrapping station 1. By movement of the product 3 with the mat 2 through the wrapping station 1, the mat 2 is in contact with the lateral sides 4, 5 and may gradually being folded inwardly due to this contacting.

In this embodiment, the wrapping station 1 is shown as a tunnel through which the product with the mat can move. According to the invention, the mat is being folded around the product by simultaneous movement in longitudinal direction and contacting the wrapping station. Contrary to the prior art, wherein the product with the mat are stationary and the mat is, either by complex robotic arms, or manually, folded around it. Instead of a tunnel wrapping station, alternatively, only lateral sides may be provided that incline upwardly such that during movement of the product with the mat along the lateral sides, the mat is being folded. No complex robotic arms are required then, or manual failure sensitive folding may be obviated. According to the invention, a relatively simple longitudinal movement of the product and mat with respect to the wrapping station may be sufficient to fold the mat around the product. An advantage of providing a tunnel and pushing the product with the mat therethrough may be that the transition to the compression station may become easier.

The wrapping station 1 of figure 1 is embodied as a tunnel having a first part la with the inclining lateral sides 4, 5 and a second part lb having a top side 6 closing the lateral sides 4, 5. The first part la and the second part lb are preferably connected to each other as to form a single wrapping station 1. However in an other embodiment, the wrapping station 1 may only comprise of the first part la having the inclining lateral sides to gradually fold the mat around the product when the product with the mat are moved along the lateral sides. The second part lb can be obviated in some embodiments as it may merely serve in the transition to the compression station (not shown in figure 1).

In addition to the lateral sides 4, 5 inclining upwardly, the wrapping station 1 is here provided with a closing element 7 to close the mat 2 around the product 3. The closing element 7 can be stationary mounted to the wrapping station 1, or can be movable, e.g. hingedly, mounted with respect to the wrapping station 1, or the closing element 7 can be an external element that gradually moves towards the wrapping station 1 to close the mat 2. In the latter embodiment, the closing element 7 may be separate from the wrapping station 1.

In this embodiment, the closing element 7 is mounted to the wrapping station 1. In particular, the closing element 7 is mounted to the top side 6 of the wrapping station 1 and bridges the gap between the lateral sides 4, 5. The closing element 7 can be stationary, then the mat gradually comes in contact with the closing element 7 during movement and can gradually being closed. Alternatively, the closing element 7 may be movable, e.g. hingedly connected to the wrapping station 1. For example, the connection 7a between the closing element 7 and the top side 6 may be embodied as a hinge. By arranging the closing element 7 hingedly connected to the wrapping station, the closing element 7 may be actuated to gradually move towards the product 3 with the mat 2 while these are being moved through the wrapping station 1.

The mat 2 is typically elongated, e.g. rectangular, with ends 2a, 2b that approximately join each other when the mat 2 is folded around the product 3. The ends 2a, 2b can be provided with joining elements, such as a finger extending from one end arranged to fit in a recess of the other end, etc. To help the ends 2a, 2b to join, the closing element 7 may be provided that may close the ends 2a, 2b together.

Figure 2a shows an alternative embodiment of the wrapping station 1 according to the invention. Here, the wrapping station 1 is embodied as a tunnel having lateral sides 4, 5 inclining upwardly towards a top side 6. Here, the tunnel 1 has an approximately circular cross-section corresponding with the circular cross-section of the product 3. The mat 2 is being folded around the product 3 by contact with the lateral sides 4, 5 during movement of the product 3 with the mat 2 through the wrapping station 1. So, the folding of the mat 2 is simultaneous to the movement of the product with the mat through the wrapping station 1.

In the embodiment of figure 2a, a pusher 8 is shown. The pusher 8 has a pushing rod 8a and a pushing disc 8b. The pushing disc 8b engages an end of the product 3 to push the product 3 through the wrapping station 1. The pushing rod 8a connects the pushing disc 8b with an actuator that provides the pushing force. Various embodiments of the pusher 8 are possible. For example, the pushing disc 8b can be provided with fingers or claws that engage around the end of the product 3 to establish a firm connection between the pushing disc 8b and the product 3. Alternatively and/or additionally to the pusher, also a stopper (not shown here) can be provided at the opposite end of the product to limit the movement of the product when being pushed.

In another embodiment of the pusher, the pushing disc 8b can be provided with a ridge extending outwardly from the pushing disc and that is arranged to hold the mat 2 onto the product 3 while the product with the mat is being pushed through the tunnel 1 and/or to prevent the mat 2 from being pushed backwardly during the movement. The ridge 8c can be provided over the whole circumference of the pushing disc 8b, but can also be provided over a limited part thereof. For example, the inventors found that it may be sufficient to provide the ridge 8c over the circumference of the pushing disc 8b, and to provide a movable ridge 8d at an upper side thereof where the tunnel 1 is open due to the inclining lateral sides 4, 5, as is shown in figure 3a and figure 3b. The movable ridge 8d can be spring mounted and as such may be pushed radially inwardly by the closing element 7 as well. The ridge 8c may prevent the ends 2 a, 2b of the mat 2 to move backwards during the pushing movement. The radially movable ridge 8d may hold the mat 2, in particular the ends 2a, 2b of the mat 2, properly positioned with respect to the product 3 and/or around the circumference of the product 3 during the pushing motion.

The mat 2 is typically somewhat shorter than the product 3, as can be seen in figure 3. Probably, such that, when compressing the mat 2 towards the product 3, in a compressing station, the length of the mat 2 can at least approach the length of the product 3. During pushing of the product 3 with the mat 2 through the wrapping station 1 and/or the compression station 12 and/or the shell station 13, backwards shifting of the mat 2 with respect to the product 3 is preferably avoided for optimal end-product quality. Advantageously, the trading edge 2c of the mat 2 is being kept in position with respect to the product 3 during movement. More advantageously, the trading edge 2c of the mat 2 is being kept in position over the circumference of the product 3. Thereto, the pusher 8 may be provided with a ridge 8c. The ridge 8c can be provided over the whole or part of the circumference of the pusher 8 and is arranged to withhold the mat 2 in position with respect to the product 3 during movement. The ridge 8c can thereto be provided with fingers or other holding means to prevent the mat 2 from shifting backwards during movement.

In the embodiment of figure 3a and figure 3b, there is a movable ridge 8d provided. The movable ridge 8d is provided at the upper end of the pusher 8, such that the position of the movable ridge 8d corresponds with the opening between the lateral sides of the wrapping station. As such, the movable ridge 8d may prevent the ends 2a, 2b from shifting backwards during the pushing movement through the wrapping station 1 and may facilitate the ends 2 a, 2b to fold into each other more smoothly. The movable ridge 8d will be pushed inwardly by the closing element 7 while the pusher 8 moves further inward into the wrapping station 1.

The movable ridge 8d on the pusher 8 can be considered as an invention on its own. According to an aspect of the invention, the pusher is provided with a movable ridge positioned at an upper side of the pusher corresponding with an opening between the upwardly inclining lateral sides of the wrapping station to hold the ends of the mat.

In the embodiment of figure 2a and figure 3, the upwardly inclining lateral sides 4, 5 have a helical fine shape. By providing this helical line shape, or spiral shape, the mat 2 comes gradually in contact with the lateral sides 4, 5, in particular with upper edges 4a, 5a thereof, such that folding of the mat 2 inwardly is also gradually. Advantageously, the mat 2 is folded gradually as to prevent or limit tearing of the mat or to prevent or limit backward movement of the mat etc. A smooth folding of the mat is advantageous to preserve the quality of the mat.

In order to allow gradual folding of the mat 2 around the product 3, the inclination angle of the inclining lateral sides is preferably between about 10 degrees and about 80 degrees, more preferably between about 20 degrees and about 70 degrees, more preferably about 30 - 35 degrees. The inclination angle a is considered to be the angle with respect to the longitudinal axis B of a fine L going from a beginning of the lateral side 4, 5 to an end of the lateral side 4, 5, as shown in the side view of figure 2b.

In the embodiment of figure 4, the tunnel 1 of figure 2 a is shown additionally provided with a closing element 7. The closing element 7, as in the embodiment of figure 1, can be fixed or movable mounted to the top side 6 of the wrapping station 1. The connection 7a may be provided as a hinge around which the closing element 7 may be swiveling. The hinge can have various embodiments, e.g. an articulating hinge may be provided or a living hinge etc. The hinge itself may be actuated, e.g. spring biased, or the hinge may be passive while the closing element 7 can be actuated. Many variants are possible.

The closing element 7 can also be fixedly mounted to the wrapping station, so the ends 2a, 2b come gradually in contact with the closing element 7 as well and can then be closed towards each other. Preferably, the closing element 7 is inclined with respect to the longitudinal axis B of the wrapping station 1. The inclination of the closing element 7 can be limited, e.g. between about 0 and about 45 degrees, preferably between about 1 degree and about 30 degrees, more preferably between about 2 degrees and about 25 degrees, more preferably between ab out 2 degrees and about 20 degrees, to provide for gradual contact of the ends 2a, 2b with the closing element 7.

Figure 5 shows an embodiment of a machine 10 comprising a wrapping station 1. The machine 10 comprising the wrapping station 1, and a receiving station 11 positioned in front of the wrapping station 1. The receiving station 11 is arranged to receive the mat 2 and the product 3. Typically, the mat and the product are laid, or pushed, in the receiving station such that the mat is positioned between the receiving station 11 and the product 3. Advantageously, the receiving station 11 has a shape that corresponds with the shape of the product 3 to ensure a correct positioning of the mat with respect to the product.

Further, the machine 10 comprising a compression station 12. In the compression station 12, the mat 2 is compressed towards the product 3. Typically, the compression station 12 is embodied as a funnel, as shown in figure 5, but other embodiments are also possible, such as providing tooling that pushes the mat towards the product. The funnel 12 has a larger cross-section at the beginning thereof, i.e. at the end of the wrapping station, than at the end thereof, i.e. at the end away from the wrapping station.

Advantageously, the funnel is provided which allows for a smooth transition of the mat-wrapped product between the wrapping station 1 and the funnel 12. In an advantageous embodiment, a pusher 8 is provided that pushes the product 3 with the mat 2 through the machine 10, from the receiving station 11 through the wrapping station 1 into the funnel 12. Another advantage of providing a funnel 12 is that the compression of the mat 2 towards the product 3 is done gradually as to prevent that the forces on the product may become too high. In particular when the product is a ceramic substrate this limiting of the forces can be important.

Further, the machine 10 is provided with a shell station 13. In the shell station 13, a shell is provided around the mat-wrapped product by means of stuffing, i.e. inserting the mat-wrapped product into a shell. The shell can be a shell that is already on the desired final diameter, then the method is call ‘hard stuffing’. Alternatively, the shell can have a diameter that is larger than the final diameter, the method is then called ‘soft stuffing’. After inserting the mat-wrapped product into the shell, the shell assembly can be reduced in diameter until the final diameter is reached, for example by means of shrinking. Both methods are well known in the art and are not elaborated on further.

The different stations of the machine 10 are preferably aligned such that in an advantageous embodiment, a single pusher or pusher/stopper combination can push the product with the mat through the machine. While this may require a relatively long pusher rod and/or stopper rod, as well as a relatively long pushing stroke, alternatively some of the stations may be positioned on another line. Care then is to be taken when displacing the mat-wrapped product from one station to another to avoid the mat coming loose and/or opening.

Figures 6a -6h show subsequent steps of the method for wrapping a mat around a product according to the invention and are explained below.

Figure 6a shows an embodiment of a machine 10 comprising a receiving station 11, a wrapping station 1, a compression station 12 and a shell station 13. In this embodiment, the different stations of the machine 10 are positioned in line with each other such that the longitudinal axes of the different stations are aligned and the product with the mat can be pushed through the machine 10 in one movement.

At one end of the machine 10 a pusher 8 is provided and at the opposite end of the machine 10 a stopper 9 is provided. The pusher/stopper combination 8-9 is arranged to push a product 3 with a mat 2 through the machine 10 from one end at the receiving station 11 to the other end at the shell station 13. Here, the machine 10 is stationary and the product 3 with the mat 2 is pushed through it.

The product 3 and the mat 2 are schematically represented. In an embodiment the product 3 can be a ceramic substrate or other catalyst support, and the mat 2 can be a washcoat as typically used in a catalytic converter.

In step 1, shown in figure 6 a, the substrate 3 and mat 2 are made ready to be transported to the receiving station 11. In step 2, shown in figure 6b, the product 3 and the mat 2 are at the receiving station 11 and are positioned in the receiving station 11 such that the mat 2 is positioned between the receiving station 11 and the product 3 as to be at an outer side of the product 3. In step 3, shown in figure 6c, the mat 2 and product 3 are in the receiving station 11 with the mat 2 underneath of the product 3 and the ends 2a, 2b of the mat 2 extending outwardly thereof. The product 3 with the mat 2 are positioned in line with the wrapping station 1. In this embodiment, the product 3 with the mat 2 are aligned with the wrapping station 1, such that the longitudinal axis A of the product 3 is in line with or parallel with the longitudinal axis B of the wrapping station 1. In step 4, shown in figure 6d, the pusher-stopper combination 8-9 moves towards the product 3 with the mat 2 in order to engage the product 3 at both ends. At one end the pusher 8 engages the product 3 and at the opposite end, the stopper 9 engages the product 3. By engaging the product 3 with the pusher 8 at one end and with the stopper 9 at the opposite end, the product 3 can be centered and clamped to align the pusher 8 and the stopper 9 with the product 3 and the machine 10. The product 3 with the mat 2 is now ready to be pushed through the wrapping station 1 by means of the pusher-stopper combination 8-9.

In step 5, shown in figure 6e, the product 3 with the mat 2 are being pushed inside of the wrapping station 1. The lateral sides 4, 5 of the wrapping station 1 are inclined upwardly, having an inclination angle of approximately 30 degrees. By contacting of the mat 2 with the lateral sides 4, 5 during axial movement through the wrapping station 1, the mat 2 is gradually being folded around the substrate 3.

In step 6, the substrate 3 with the mat 2 is pushed further through the wrapping station 1 and the mat 2 is being folded further around the product 3. The ends 2a, 2b are still open and need to be joined. To improve joining of both ends 2a, 2b, one end 2a is provided with an opening in which a finger of the other end 2b fits. By providing such connecting elements as for example the opening and the finger, a more firm connection can be achieved to close the mat 2 at the ends 2a, 2b. Other connecting elements are of course also possible. The substrate 3 with the mat 2 approach the closing element 7 arranged to close the ends 2a, 2b of the mat 2. Here, the closing element 7 is fixedly mounted to the wrapping station 1 at an upper end thereof. The ends 2a, 2b come gradually in contact with the closing element 7 that guides the ends 2a, 2b towards each other to close the mat 2 around the substrate 3.

In step 7, shown in figure 6g, the substrate 3 with the mat 2 is pushed further inside of the wrapping station 1 and the closing element 7 further guides the ends 2a, 2b towards each other to close the mat 2.

Then, in step 8, the pusher-stopper combination 8-9 pushes the substrate 3 with the mat 2 folded around it further through the machine 10 into the compression station 12 and then into the shell 14 of the catalytic converter as can be seen in figure 6h. The compression station 12 is here embodied as a funnel 12 having a larger opening at the side 12a adjacent the wrapping station 1 and a smaller opening at the opposite side 12b thereof. The reduction of the diameter of the funnel 12 is schematically shown. Due to the reduction of the diameter, the mat 2 is compressed towards the substrate 3 while the substrate 3 and the mat 2 are being pushed through the funnel 12 to reduce the overall diameter of the mat-wrapped substrate such that it can be stuffed into the shell 14 of the shell station 13. The shell station 13 is here a stuffing station, meaning that the mat-wrapped substrate is being inserted, e.g. pushed, inside of the shell 14.

The receiving station 11, the wrapping station 1, the compression station 12 and the shell station 13 can be embodied as different parts that are joined together, or can be provided as a single part having all the different functions of receiving, wrapping, compressing and stuffing.

The machine 10 or at least the wrapping station 1 can be positioned in horizontal direction, meaning that the longitudinal direction approximately parallel to a horizontal direction. The substrate 3 with the mat 2 can then be pushed through the machine 10 from left to right or from right to left, when all stations are positioned in fine. Alternatively, the machine 10, or the wrapping station 1, can be positioned vertically, meaning that the longitudinal direction thereof is approximately parallel to a vertical direction. Then, the substrate 3 and the mat 2 can be pushed through the machine 10, or wrapping station 1, in an upward direction or in a downward direction, thereby reducing the footprint of the machine.

For the purpose of clarity and a concise description, features are described herein as part of the same or separate embodiments, however, it will be appreciated that the scope of the invention may include embodiments having combinations of all or some of the features described.

It may be understood that the embodiments shown have the same or similar components, apart from where they are described as being different.

In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word ‘comprising’ does not exclude the presence of other features or steps than those listed in a claim. Furthermore, the words ‘a’ and ‘an’ shall not be construed as limited to ‘only one’, but instead are used to mean ‘at least one’, and do not exclude a plurality. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to an advantage.

Many variants will be apparent to the person skilled in the art.

All variants are understood to be comprised within the scope of the invention defined in the following claims.

Claims (24)

Method for wrapping a mat around a product, comprising: - providing a wrapping station; - placing the mat and the product at an entrance to the winding station; - moving the product with the mat and the winding station relative to each other in a longitudinal direction of the winding station; whereby the mat is wrapped around the product by contact with the wrapping station, while at the same time the mat and the product are moved relative to the wrapping station. A method according to claim 1, wherein the winding station has lateral sides that slope upwards to an upper side of the winding station, such that when moving the product with the mat and the winding station, relative to each other in the longitudinal direction of the winding station, the mat is gradually wound through simultaneous contact with the lateral sides. Method according to claim 1 or 2, wherein a closing element is provided for closing the mat around the product while the product moves with respect to each other with the mat and the winding station. Method according to claim 3, wherein the closing element moves gradually towards the product for gradually closing the mat around the product, while at the same time moving the product with the mat and the winding station relative to each other. Method according to claim 3 or 4, wherein the closing element is mounted on the winding station. A method for introducing a mat-wrapped product into a casing, comprising wrapping the mat around the product according to the method of any one of claims 1-5, further comprising compressing the mat toward the product at a compression station , like a funnel. The method of claim 6, wherein the method further comprises providing a wrapper around the mat-wrapped product. The method of claim 7, wherein the casing is provided around the mat-wrapped product by pushing the mat-wrapped product into the casing. 9. Winding station for winding a mat around a product, the winding station being adapted to receive the mat and the product in a longitudinal direction thereof, the winding station comprising two lateral sides which slope upwards to an upper side of the winding station, such that during the movement of the product and the mat relative to the winding station, the mat is wrapped around the product by simultaneous contact with the lateral sides. The winding station of claim 9, wherein the lateral sides are inclined upward in a spiral line shape. The wrapping station of any one of claims 9-10, wherein an angle of inclination of the lateral sides relative to the longitudinal direction is between about 10 to about 80 degrees. A wrapping station as claimed in any one of claims 9-11, further comprising a closing element adapted to close the mat around the product while the product and the mat, and the wrapping station, move relative to each other. The winding station of claim 12, wherein the closing element is adapted to partially close an opening between the lateral sides on the top of the winding station. 14. Winding station according to claim 12 or 13, wherein the closing element is mounted on the winding station. The wrapping station of claim 14, wherein the closing element is pivotally mounted on the top of the wrapping station. The wrapping station of any one of claims 9-15, wherein the wrapping station and the product have corresponding cross sections. 17. Winding station according to any of claims 9-16, further comprising a pushing member for pushing the product and the mat through the winding station. The winding station of claim 17, wherein the push member comprises a movable cam. The winding station according to any of claims 9-18, wherein the winding station comprises a tunnel. A machine for providing a mat-wrapped product in a casing, the machine comprising a wrapping station as claimed in any one of claims 9-19, further comprising a pick-up station disposed in front of the wrapping station for receiving the mat and the product. The machine of claim 20, further comprising a compression station disposed behind the winding station for compressing the mat toward the product. The machine of claim 20 or 21, further comprising an encapsulating station disposed behind the compression station, wherein the encapsulating station is a pushing station in which the matte-wrapped product is pushed into the enclosure. The machine according to any of claims 20-22, further comprising a push member for pushing the mat and product from the pick-up station through the winding station through the compression station in the casing of the casing station. 24. Pushing device adapted to push a product with a mat through a winding station and / or a machine, wherein the winding station is a winding station according to one of claims 9-19 and / or the machine is a machine according to one of claims 20-23 wherein the pushing member is provided with a movable cam disposed on an upper side of the pushing member corresponding to an opening between the upwardly inclined lateral sides of the winding station for holding the ends of the mat.