Airflow-Controlled Winding of Edge-Coated Belt Structures
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Solution Overview
Problem
The challenge in winding a band-shaped structure with an edge-coating film is to prevent mismatching and local lumps due to bends and folds of the edge-coating part around the winding core, which can lead to short circuits and damage.
Innovation Solution
A winding apparatus with an air flow controller that adjusts the air flow near the edge-coating part using a nozzle for either ejection or suction, ensuring precise alignment and minimizing bends and folds during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the edge-coating part of the film protrudes from the edge of the substrate during winding, then the substrate edge is covered for short circuit prevention, but bends and folds occur in the edge-coating part causing mismatching and local lumps
Solution Approach 1:
A guide roller is introduced as an intermediary component between the winding core and the edge-coating part. The guide roller has a curved surface that guides the edge-coating part along its contour, preventing direct contact and bending against the winding core. This intermediary structure maintains the protective coverage function while eliminating the bending and folding problems that cause alignment errors and local lumps.
2Manufacturing precision
If the edge-coating part is kept flat during winding, then alignment precision is maintained, but the edge of the substrate is not adequately covered
Solution Approach 1:
The solution moves the interaction from a two-dimensional plane contact to a three-dimensional curved surface guidance. The guide roller provides a curved surface that allows the edge-coating part to wrap around it, creating a controlled three-dimensional path that maintains flatness while achieving the necessary coverage protrusion for short circuit prevention.
3Productivity
If the winding speed is increased to improve productivity, then output increases, but bends and folds in the edge-coating part occur more frequently
Solution Approach 1:
The guide roller is positioned upstream in the winding process to pre-guide the edge-coating part along its curved surface before the material reaches the winding core. This preliminary guidance action prevents the formation of bends and folds at the critical winding interface, allowing high-speed winding without compromising alignment precision.
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
This solution effectively suppresses bends and folds of the edge-coating film, preventing mismatching and local lumps, thus enhancing the quality and integrity of the wound band-shaped structure.
Implementation Method 1
an air flow controller having a nozzle that performs at least either ejection or suction of a gas
Data Source
AI summary
According to an embodiment, a winding apparatus includes a winding core and an air flow controller. The winding core winds a belt-shaped structure comprising a substrate and an edge-coating part that covers an edge of a substrate in a width direction, the edge-coating part being coated with a material liquid on a surface of the substrate. The air flow controller has a nozzle that performs at least either ejection or suction of a gas, and adjusts an air flow in the vicinity of the edge-coating part of the film of the belt-shaped structure, which is wound by a winding core.