Blank Joining Module With Contact Roller for Fiber-Safe Alignment

A contact roller is introduced as an intermediary element between the pressure application system and the blanks. The roller indirectly applies pressure to the composed blank by rolling over it, distributing the force along the junction point rather than concentrating it at a single location. This mediator approach maintains joining strength while preventing localized fiber rupture that would occur with direct pressure application.

The pressure application method is changed from static direct pressure to dynamic rolling pressure. The contact roller moves along the junction point, continuously applying pressure through rotation rather than sustained static force. This parameter change in pressure application mode allows effective joining while reducing the risk of fiber damage through distributed temporal and spatial pressure distribution.

The contact roller provides a curved surface that gradually guides the upper blank onto the lower blank. Instead of a sharp angular positioning that would cause sudden fiber stress, the roller's cylindrical surface creates a gradual transition zone. This curvature allows the blank to be positioned at speed while distributing the mechanical stress over a longer path, preventing fiber bending and breaking.

The contact roller acts as a cushioning element before the full joining pressure is applied. As the upper blank is positioned onto the lower blank, the roller first makes contact and gradually increases pressure, cushioning the transition and preventing sudden impacts that would bend or break fibers during the alignment process.