Adhesive Leveler Cleaning Sheets for In-Line Roll Cleaning
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Solution Overview
Problem
Conventional methods for cleaning leveler machine rolls are time-consuming, require skilled personnel, and often involve expensive and environmentally unfriendly solvents, with inefficient cleaning processes that are difficult for a single operator to perform effectively.
Innovation Solution
A leveler cleaning sheet with a substrate and multiple adhesive layers, specifically designed to adhere to ferrous and non-ferrous metals, is used for in-line cleaning by rotating the rolls, allowing for efficient and cost-effective removal of contaminants with minimal production loss and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional cleaning methods (manual cleaning, solvent spraying) are used, then cleaning effectiveness is achieved, but cleaning time is excessive (30 minutes per step) and production efficiency is reduced
Solution Approach 1:
The patent employs disposable cleaning sheets with adhesive layers that are applied to the roll surface, used for cleaning, and then discarded. This eliminates the need for time-consuming manual cleaning procedures and solvent-based methods, reducing cleaning time from 30 minutes to a fraction of that time while maintaining effective contaminant removal.
Solution Approach 2:
The cleaning sheets are prepared in advance with adhesive layers that are designed to optimally adhere to and remove contaminants. The adhesive properties are pre-configured to ensure effective cleaning upon contact, eliminating the need for complex manual cleaning procedures during production.
2Productivity
If in-line cleaning methods are implemented, then production efficiency is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The cleaning sheets are designed to be self-applied and self-executing. The operator simply applies the adhesive cleaning sheet to the roll, and the roll's rotation automatically performs the cleaning action as it passes through the leveler. This eliminates complex mechanical cleaning devices, scrapers, or automated cleaning mechanisms that would increase system complexity and maintenance requirements.
3Measurement precision
If organic solvents are used for cleaning, then contaminant removal is effective, but environmental impact and operational complexity increase
Solution Approach 1:
The patent replaces organic solvent-based cleaning methods with disposable adhesive cleaning sheets. The sheets physically adhere to and remove contaminants through their adhesive properties without requiring chemical solvents. This eliminates environmental concerns associated with solvent disposal and reduces operational complexity related to solvent handling and safety protocols.
4Measurement precision
If conventional cleaning sheets are used, then cleaning function is provided, but ease of operation is reduced requiring multiple operators
Solution Approach 1:
The cleaning sheet integrates multiple functions into a single component: the substrate provides structural support, the adhesive layer provides contaminant removal, and the combination allows the sheet to be applied and executed by a single operator. The integrated design eliminates the need for separate preparation and execution steps that would require multiple operators.
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
The method significantly reduces cleaning time, improves production efficiency, and allows for simple, single-operator operation while being environmentally friendly, effectively removing contaminants with a single pass through the leveler machine.
Implementation Method 1
the first adhesive layer exhibits an adhesion to ferrous or non-ferrous metals of higher than 10 cN/20mm
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3D
AI summary
Method of cleaning the rolls of a leveler machine (6), such as the work rolls of a tension leveler, for example, the method comprising the steps of: contacting a leveler cleaning sheet (20) with at least a part of the curved surface of the one or more rolls to enable cleaning by rotation of the one or more rolls; the leveler cleaning sheet (20) comprising a substrate (21) and a first adhesive layer (22) provided over the substrate (21), and the surface of first adhesive layer (22) contacting at least a part of the curved surface of the one or more rolls; wherein the first adhesive layer (22) exhibits an adhesion to ferrous or non-ferrous metals of higher than 10 cN/20mm. In addition, a method of manufacturing a leveler cleaning sheet (20) and to leveler cleaning sheets (20) produced by said method.