Adjustable Support Roller Structure for Thin Film Wrinkle Prevention
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Solution Overview
Problem
Existing rollers fail to prevent wrinkles in thin film materials during manufacturing processes, which can lead to defects in secondary batteries and other flexible materials.
Innovation Solution
A roller design featuring a rotation shaft, pipe, deforming part, and support part, with adjustable tension control through a thread and nut mechanism, allowing for flexible support and wrinkle prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple roller structure is used to support the material, then the device complexity is reduced, but the material surface quality deteriorates due to wrinkle formation
Solution Approach 1:
The roller incorporates an adjustable tension mechanism that allows the pipe to dynamically adapt its tensioning force to match different material characteristics. The nut part can be positioned at various locations along the thread portion to adjust the degree of pipe deformation, enabling the roller to maintain optimal support tension for different material types and thicknesses, thereby preventing wrinkles while managing structural complexity
Solution Approach 2:
The invention changes the tension parameter of the pipe by deforming it through the deforming part. By adjusting the position of the nut part on the thread portion, the degree of pipe deformation is modified, which directly changes the tension applied to the material. This parameter adjustment allows the roller to prevent wrinkles without requiring a completely complex structure
2Device complexity
If a fixed tension roller is used, then the device complexity is reduced, but the adaptability to different material characteristics deteriorates
Solution Approach 1:
The roller transitions from a fixed tension design to a dynamically adjustable one. The nut part can be repositioned along the thread portion to change the deformation amount of the pipe, allowing the roller to adapt to different material characteristics such as thickness, flexibility, and tension requirements while maintaining a relatively simple overall structure
Solution Approach 2:
The adjustable tension mechanism provides multi-functionality to the roller, enabling it to handle various material types (thin films, flexible materials, different thicknesses) with a single device. The same roller structure can be configured for different applications by simply repositioning the nut part, eliminating the need for multiple specialized rollers
3Manufacturing precision
If the pipe is highly deformed to increase tension control, then the manufacturing precision is improved, but the device complexity increases due to additional deforming components
Solution Approach 1:
The deforming part applies localized deformation to the pipe at a specific position where the nut part contacts it. This focused deformation approach achieves effective tension control and wrinkle prevention without requiring complex deformation mechanisms throughout the entire roller structure. The thread portion and nut part combination provides precise local control with minimal additional components
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 roller effectively supports materials by adjusting tension to match their characteristics, preventing wrinkles and ensuring high-quality production.
Implementation Method 1
a deforming part (18) connected to the rotation shaft (12) and the pipe (14) to deform the pipe (14). The deforming part (18) includes: a thread portion (180) provided on the rotation shaft (12); a nut part (182) screwed to the thread portion (180); an inclined part (184) that is disposed at an inner surface of the pipe (14) and that is pressed by the nut part (182) according to rotation of the rotation shaft (12)
Data Source
AI summary
A roller for supporting a material according to an embodiment of the present invention includes: a rotation shaft; a pipe having a space in which the rotation shaft is inserted; a deforming part that is connected to the rotation shaft and the pipe to deform the pipe; and a support part that is installed at the pipe to support the material. The deforming part includes: a thread portion provided on the rotation shaft; a nut part screwed to the thread portion; an inclined part that is disposed at an inner surface of the pipe and that is pressed by the nut part according to rotation of the rotation shaft; and a driving source that is connected to the rotation shaft to rotate the rotation shaft.