Adhesive Tape Roll Perforation With Synchronized Rollers

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Solution Overview

Problem

Existing methods for forming cut lines in adhesive tape rolls for cleaning, such as laser beam machining and rotary blades, result in deformation, scorching, and reduced productivity due to the need for precise control and consideration of tape thickness, leading to inefficient and wasteful cutting processes.

Innovation Solution

A method involving synchronization of a winding roller and a cut-lines formation roller via gears with adjustable gear ratios to intermittently form cut lines at predetermined intervals, preventing deformation and ensuring consistent cutting positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If press-cutting blade is inserted to form perforations, then cut lines are formed, but adhesive tape is lifted up and caught in the blade side face causing deformation into onion shape

Engineering Contradiction:

Improvecut line formationVSAvoidadhesive tape roll shape

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The harmful function of the press-cutting blade (lifting and catching adhesive tape) is completely removed from the system. Instead of using a blade that contacts and damages the adhesive tape, the patent extracts this harmful element and replaces it with a non-contact laser beam method that forms cut lines without mechanical interaction with the adhesive tape surface.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical press-cutting blade system is replaced with a non-contact laser beam system. The laser beam substitutes the mechanical cutting action, eliminating the harmful mechanical interaction that causes adhesive tape to be lifted and caught in the blade, thereby preventing onion shape deformation while still achieving cut line formation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If laser beam machining is used to form cut lines, then deformation is prevented, but adhesive tape is burned off causing scorch and ruining appearance

Engineering Contradiction:

Improveadhesive tape roll shapeVSAvoidscorch and burn off

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The laser beam parameters (power, pulse duration, frequency) are precisely controlled and optimized to achieve cut line formation without excessive heat input. By adjusting these parameters, the laser energy is sufficient to create the desired perforations but not so high as to cause burning or scorching of the adhesive tape, thus resolving the contradiction between preventing deformation and avoiding thermal damage.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If rotary blade is used with constant cycle rotation, then cut lines are formed, but control becomes cumbersome due to varying tape thickness

Engineering Contradiction:

Improvecut line formationVSAvoidcontrol system complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The complex mechanical rotary blade system with clutch control is replaced by a laser beam system that can be precisely controlled by computer or programmable logic controller. The laser beam's position and activation are controlled through digital signals, eliminating the need for mechanical synchronization mechanisms and making the system easier to control despite variations in tape thickness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser beam system incorporates dynamic adjustment capabilities that allow real-time adaptation to varying tape thickness. The control system can dynamically adjust laser parameters and positioning based on feedback or pre-programmed data, making the manufacturing process more flexible and easier to control compared to the fixed-cycle rotary blade system.

Inventive Principle:

Principle #15Dynamics

4Ease of manufacture

If press-cutting blade is used, then cut lines are formed, but productivity is decreased due to deformation and waste

Engineering Contradiction:

Improvecut line formationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The replacement of the mechanical press-cutting blade with a laser beam system eliminates deformation and waste, resulting in higher productivity. The laser beam method produces clean cuts without onion shape deformation, reducing or eliminating the need for rework or scrap disposal, thereby improving manufacturing efficiency and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potential harm of laser beam machining (over-burning) into a benefit by precisely controlling the laser parameters. This precise control ensures that the laser energy is optimized to create clean cut lines without causing damage, thereby transforming a potentially harmful process into a beneficial one that improves productivity by eliminating waste and rework.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS9017508B2Adhesive tape roll and method for manufacturing adhesive tape roll

Publication Date: 2015.04.28 NITOMS INC

AI summary

Disclosed is a technique of manufacturing an adhesive tape roll by which cut lines for cutting an adhesive tape can be regularly formed at a constant position. Provided are a winding roller (32) that winds the adhesive tape (2) fed out from a mother roll (31) and a cut-lines formation roller (33) that is provided between the mother roll (31) and the winding roller (32) and forms the cut lines (4) in the adhesive tape (2) at a predetermined interval. The winding roller (32) and the cut-lines formation roller (33) are rotated in synchronization with each other via predetermined gears (40).