Belt-Driven Feed Roller Dispenser to Reduce Gear Noise and Wear
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Solution Overview
Problem
Existing dispensers for flexible sheet materials, such as paper products, often produce noise and apply inconsistent forces, leading to improper feeding and reduced component lifespan due to the use of intermeshing gears.
Innovation Solution
A dispenser assembly with a feed roller drive system utilizing a belt transmission assembly and a motor mounted within the dispenser housing, which includes a tensioner assembly to maintain consistent belt tension and reduce noise, ensuring consistent and quiet dispensing of sheet materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If intermeshing gears are used in the drive mechanism, then automatic driving function is achieved, but significant noise is generated during operation
Solution Approach 1:
The patent replaces the traditional intermeshing gear mechanical transmission system with a belt-driven pulley system. The motor drives a pulley that is connected to the feed roller via a belt, eliminating the gear meshing action that generates noise while maintaining the automatic driving function. This substitution of mechanical transmission methods directly addresses the noise problem while preserving automation.
2Extent of automation
If intermeshing gears are used in the drive mechanism, then automatic driving function is achieved, but inconsistent driving force is applied to the sheet material
Solution Approach 1:
The belt-driven pulley system provides smoother and more consistent force transmission compared to intermeshing gears. The continuous belt contact with the pulleys ensures uniform driving force application to the feed roller, which in turn consistently feeds the sheet material without the intermittent force characteristics of gear engagement.
3Extent of automation
If intermeshing gears are used in the drive mechanism, then automatic driving function is achieved, but increased wearing of parts occurs
Solution Approach 1:
The belt-pulley system eliminates the toothed gear contact that causes wear through friction and impact. The belt provides continuous, smooth contact with the pulleys, significantly reducing wear on the feed roller and drive components. This extends the operational life of stationary parts while maintaining the automatic driving capability.
4Object-generated harmful factors
If belt transmission assembly is used instead of gears, then noise is reduced, but device complexity increases
Solution Approach 1:
The patent extracts the noisy gear meshing elements from the drive system and replaces them with separate motor, pulley, and belt components. This extraction of the problematic gear mechanism allows for a quieter operation while the modular nature of the belt-driven components keeps the overall structural complexity manageable.
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 solution provides a quiet and consistent dispensing of sheet materials, reducing noise and wear on components, while extending the lifespan of the feed roller and drive belt, and allowing for reduced power usage.
Implementation Method 1
a belt transmission assembly for transferring power between the motor and the feed roller. The belt transmission assembly includes a drive belt extending between the drive motor and feed roller
Implementation Method 2
one or more pressing rollers that are biased toward engagement with the feed roller so that the sheet material is urged and/or engaged against the feed roller
Data Source
AI summary
The present disclosure is in one aspect to a dispenser for rolled sheet materials. The dispenser includes a feed roller that is rotatably mounted to a housing of the dispenser housing, and that is configured to feed a predetermined amount of sheet material from the supply of sheet material through a discharge provided along the housing of the dispenser. The dispenser also has a feed roller drive assembly with a drive motor, and a belt transmission assembly. The belt transmission assembly has a drive belt coupled to the drive motor and to the feed roller such that rotation of the feed roller is driven by operation of the drive motor.