Angular Profile Forming with Adjustable Rollers
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Solution Overview
Problem
Existing methods for manufacturing profiles of angular section from flexible materials like paper and cardboard face issues such as tension-related defects, imperfect bonding, and dimensional inaccuracies due to bending and unwinding stresses, leading to variations in angles and geometry, especially when using coils with uneven edges.
Innovation Solution
A process involving the use of a fixed forming mandrel with angularly adjustable rollers to apply pressure and neutralize bending tensions, ensuring precise formation of profiles by adjusting the angle and geometry of the corners, and optionally incorporating temperature control and edge detection systems for automated precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional progressive bending and forming methods are used, then the manufacturing process is simple, but tension-related defects and dimensional inaccuracies occur at corner locations
Solution Approach 1:
The patent applies dynamics by making the forming rollers angularly adjustable during the forming process. This allows the rollers to adapt their angle dynamically to compensate for tensions and ensure precise angular sections, resolving the contradiction between precision and simplicity by introducing controlled adjustability rather than fixed complex mechanisms
Solution Approach 2:
The patent changes the geometric parameters of the forming process by allowing angular adjustment of rollers during forming. This parameter change enables precise control over corner geometry and angular sections, achieving high manufacturing precision without requiring overly complex fixed mechanisms
2Stability of the object's composition
If greater folding is applied to stabilize adjacent wings, then angular stability improves, but achieving precise 90° angles becomes difficult and random
Solution Approach 1:
The patent implements feedback by using angularly adjustable rollers that can be positioned to achieve exact angular sections. The adjustability allows real-time correction and verification of angles, providing feedback control that ensures both stability and precision, eliminating the randomness of greater folding methods
Solution Approach 2:
By making the rollers angularly adjustable, the system dynamically adapts to achieve precise angles while maintaining stability. This dynamic adjustment capability allows the process to achieve both angular stability and precision simultaneously, rather than sacrificing one for the other
3Adaptability or versatility
If coils with slightly different edge lengths are used, then material flexibility is maintained, but longitudinal tensions appear on flanges causing twisting and bonding defects
Solution Approach 1:
The patent replaces the traditional mechanical forming system with angularly adjustable rollers that apply controlled pressure and geometry. This substitution allows the system to compensate for variations in coil edge lengths by adapting the forming pressure and angle, maintaining bonding quality while preserving material flexibility
Solution Approach 2:
By changing the forming parameters through angular adjustment of rollers, the system adapts to variations in material dimensions. This parameter change allows consistent bonding quality regardless of coil variations, maintaining both flexibility and reliability
4Manufacturing precision
If heating molds with temperature regulation are used, then some tension problems are reduced, but tensions in the angle profile remain and dimensional tolerance is not achieved
Solution Approach 1:
The patent applies dynamics by making rollers angularly adjustable in addition to heating capabilities. This dynamic adjustment allows precise control over angular sections and dimensional tolerances, achieving the required precision without excessive complexity by focusing adjustability on critical angular parameters
Solution Approach 2:
The patent changes multiple parameters simultaneously - both temperature (through heating molds) and geometry (through angularly adjustable rollers). This combined parameter change approach achieves dimensional tolerance and eliminates angle tensions more effectively than temperature regulation alone, without proportionally increasing complexity
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 approach allows for the production of profiles with high dimensional and shape stability, precise angular sections, and consistent geometry, effectively overcoming the limitations of traditional methods by neutralizing tensions and enabling precise control over the manufacturing process.
Implementation Method 1
passing the unrolled strips over different return rollers, these strips being guided so as to present themselves one above the other, in number corresponding to the thickness of the profile to be obtained. The strips thus arranged are then directed either through a heat-sealing device
Implementation Method 2
directed either through a heat-sealing device or through a gluing device, where they are coated with glue on one or both sides
Data Source
Figure 1
Figure 2~5
Figure 3~4
AI summary
The method involves realizing forming of a profile on a fixed forming mandrel (2) by permitting pressurized application of sides of a profiled preform respectively on faces of the mandrel by using angularly adjustable rollers (3, 4) through faces of the mandrel. The forming is realized after reeling bands made of flexible material and guided horizontally through a heat sealing or gluing device coating a face of the internal bands and an internal face of the external bands. The forming is realized for assembling the glued bands into a strip and for performing the strip in the preform. An independent claim is also included for a device for forming profiles having an angular section.